JLG 4013PS Service Manual

Download

An Oshkosh Corporation Company

Service Manual

Models 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS,

4017PS,

Agrovector

40.8, 40.9

31200206

Revised

June 15, 2011

EFFECTIV IT Y PAGE

September 11, 2007 - A - Original Issue Of Manual April 4, 2008 - B - Revised pages 2.7, 2-8, 3.12, 3.27, 5.11, 7.3, 7.7, 7.8, 8.2, 8.9, 9.10, 9.28 and pages 9.30 thru 9.70.

Added platform information. June 15, 2011 - C - Update all

Loctite® 242

, to Loctite

Revised pages 1-3, 2-3 thru 2-9, 2-13, 8-6 thru 8-16, 9-11 thru 9-21 & 9-34 thru 9-45.

243

. Added models 40.8 & 40.9. Revised page numbering.

31200206 3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

EFFECTIV IT Y PAGE

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9 31200206

SECTION CONTENTS

Section Subject Page

Section 1

Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Operation & Safety Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.4 Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.5 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

Section 2

General Information and Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 Replacement Parts and Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

2.3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

2.5 Maintenance Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

Section 3

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Boom System Component Terminology - Two and Three Section Boom . . . . . . . . . . . 3.3

3.2 Boom System - Two and Three Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

3.3 Boom Assembly Maintenance - Two and Three Section Boom. . . . . . . . . . . . . . . . . . . 3.4

3.4 Boom System Component Terminology - Four Section Boom. . . . . . . . . . . . . . . . . . . . 3.8

3.5 Boom System - Four Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

3.6 Boom Assembly Maintenance - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

3.7 Boom Extend and Retract Chains Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

3.8 Boom Section Separation Adjustment - Four Section Boom . . . . . . . . . . . . . . . . . . . . . 3.21

3.9 Hose Carrier Assembly - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

3.10 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

3.11 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

3.12 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

3.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

Section 4

Cab and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3

4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section Subject Page

Section 5

Axles, Drive Shafts, Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

5.1 Axle, Drive Shaft and Wheel Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.3 Axle Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

5.4 Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11

5.7 Towing A Disabled Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12

Section 6

Transmission: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

6.2 Transmission Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.4 Transmission Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3

6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

Section 7

Engine: Perkins 1104-42 & 1104-42T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

7.2 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.3 Specifications and Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6

7.7 Engine Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

7.8 Air Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.9 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9

7.10 Engine Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12

7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13

Section 8

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.1 Hydraulic Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

8.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.3 Hydraulic Pressure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

8.4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4

8.5 Hydraulic Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

8.6 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17

8.7 Hydraulic System Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18

8.8 Auxiliary Pump (Platform Equipped Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20

8.9 Valves and Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20

8.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section Subject Page

Section 9

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

9.1 Electrical Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

9.3 Platform Interlock Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

9.4 Software Level 2 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

9.5 Operator Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7

9.6 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

9.7 Electrical System Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

9.8 Circuit Breakdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22

9.9 Engine Start Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24

9.10 Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

9.11 Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26

9.12 Window Wiper/Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26

9.13 Cab Heater and Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28

9.14 Switches, Solenoids, Sensors and Senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29

9.15 Load Stability Indicator (LSI) 8, 9, 12 & 13M Before S/N 1160005993 excluding 1160005949 & 1160005950 17M Before S/N 1160005937 including 1160005952, 1160005960, 1160005963,

1160005966 & 1160005978. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34

9.16 Load Stability Indicator (LSI) 8, 9, 12 & 13M S/N 1160005993 & After including 1160005949 & 1160005950 17M S/N 1160005937 & After excluding 1160005952, 1160005960, 1160005963,

1160005966 & 1160005978. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38

9.17 Hand Held Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.43

9.18 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.46

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

iii

Section Subject Page

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section 1

Safety Practices

Contents

PARAGRAPH TITLE PAGE

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.2 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Operation & Safety Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5.1 Safety Alert System and Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.6 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.3 General Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.7 Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

1-1

Safety Practices

1.1 INTRODUCTION

This service manual provides general directions for accomplishing servic e and re pai r proc edu res. Fo ll owi ng the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally appro ved safe ty p r actices, procedures, rules, codes, regulations and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during opera tion, maintenance, or testing. When additi onal information is desired consult the local JLG distributor.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator seat looking in a forwar d direction.

Supplementary information is available from JLG in the form of Service Bulletins, Service Campaigns, Service Training Schools, the JLG website, other literature, and through updates to the manual itself.

1.2 DISCLAIMER

1.4 DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1.5 SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

1.5.1 Safety Alert System and Signal Words

DANGER

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or serious injury.

WARNING

All information in this manual is based on the latest product information available at the time of publication. JLG reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3 OPERATION & SAFETY MANUAL

The mechanic must not operate the machine until the Operation & Safety Manual has been read and understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operation & Safety Manual is supplied with each machine and must be kept in the cab. In the event that the Operation & Safety Manual is missing, consult the local

JLG distributor before proceeding.

1-2

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate injury.

Safety Practices

1.6 SAFETY INSTRUCTIONS

Following are general safety statements to consider before performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructi ons to prov ide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions before

1.6.1 Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2 Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tool s onl y as re co mme nde d.

proceeding.

1.6.3 General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Im mediately clean, dress and report a ll injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection, and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure the machine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, it is recommended a maximum pressure of 52 bar (750 psi) at a minimum distance of 30,5 cm (12 in) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation,

Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

1.6.4 Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without ade quat e ventila tion.

SOFT SURFACES AND SLO P ES : NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the whe els blocked before performing any service.

FLUID TEMPERATURE: NEVER work on a machine when the engine, cooling or hydraulic systems are hot. Hot components and fluids can cause severe burns. Allow systems to cool before proceeding.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection. NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

1-3

Safety Practices

pressure can explode. Hydraulic oil and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.

RADIATOR CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the radiator cap while the cooling system is hot. Wear safety glasses. Turn the radiator cap to the first stop and allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic oil are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explos ion.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings. Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery.Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7 SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Safety Manual supplied with machine for information.

1-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section 2

General Information and Specifications

Contents

PARAGRAPH TITLE PAGE

2.1 Replacement Parts and Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.2 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.1 SAE Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.2 Metric Fastener Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.2.3 Hydraulic Hose Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.1 Travel Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.3.2 Hydraulic Cylinder Performance Specifications. . . . . . . . . . . . . . . . . . . . . 2-11

2.3.3 Platform Hydraulic Performance Specifications . . . . . . . . . . . . . . . . . . . . 2-11

2.3.4 Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3.5 Engine Performance Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.3.6 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.4 Fluids, Lubricants and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2.5 Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5.1 8 & 1st 50 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5.2 50, 250 & 500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.5.3 1000 & 1500 Hour Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 2-15

2.6 Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.6.1 8 Hour Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2.6.2 50 Hour Lubrication Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-1

General Information and Specifications

MZ1780

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

For reference when ordering replacement parts or making service inquiries about the machine, the machine serial number is required to help assure the provision of correct parts and information. Before ordering parts or initiating service inquiries, make note of the serial number located on the serial number plate (1).

Note: The replacement of any part on this machine with any other than a JLG authorized replacement part can adversely affect the performance, durability, or safety of the machine, and will void the warranty. JLG disclaims liability for any claims or damages, whether regarding property damage, personal injury or death arising out of the use of unauthorized replacement parts.

A warranty registration form must be filled out by the JLG distributor, signed by the purchaser and returned to JLG when the machine is sold and/or put into use.

Registration activates the warranty period and helps to assure that warranty claims are promptly processed. To guarantee full warranty service, verify that the distributor has returned the business reply card of the warranty registration form to JLG.

2-2

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2.2 TORQUE CHARTS

REFERENCE JLG ANEROBIC THREAD LOCKING COMPOUND

Description

0100011

242

Vibra-TITETM121

Medium Strength (Blue)

0100019

271

Vibra-TITETM140

High Strength (Red)

0100071

262

Vibra-TITETM131

Medium - High Strength (Red)

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604 380 8 0.9 6 0.7

48 0.1120 0.00661 420 9 1.0 7 0.8

6 32 0.1380 0.00909 580 16 1.8 12 1.4

40 0.1380 0.01015 610 18 2.0 13 1.5

8 32 0.1640 0.01400 900 30 3.4 22 2.5

36 0.1640 0.01474 940 31 3.5 23 2.6

10 24 0.1900 0.01750 1120 43 4.8 32 3.5

32 0.1900 0.02000 1285 49 5.5 36 4

1/4 20 0.2500 0.0318 2020 96 10.8 75 9 105 12

28 0.2500 0.0364 2320 120 13.5 86 10 135 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 3340 17 23 13 18 19 26 16 22

24 0.3125 0.0580 3700 19 26 14 19 21 29 17 23

3/8 16 0.3750 0.0775 4940 30 41 23 31 35 48 28 38

24 0.3750 0.0878 5600 35 47 25 34 40 54 32 43

7/16 14 0.4375 0.1063 6800 50 68 35 47 55 75 45 61

20 0.4375 0.1187 7550 55 75 40 54 60 82 50 68

1/2 13 0.5000 0.1419 9050 75 102 55 75 85 116 68 92

20 0.5000 0.1599 10700 90 122 65 88 100 136 80 108

9/16 12 0.5625 0.1820 11600 110 149 80 108 120 163 98 133

18 0.5625 0.2030 12950 120 163 90 122 135 184 109 148

5/8 11 0.6250 0.2260 14400 150 203 110 149 165 224 135 183

18 0.6250 0.2560 16300 170 230 130 176 190 258 153 207

3/4 10 0.7500 0.3340 21300 260 353 200 271 285 388 240 325

16 0.7500 0.3730 23800 300 407 220 298 330 449 268 363

7/8 9 0.8750 0.4620 29400 430 583 320 434 475 646 386 523

14 0.8750 0.5090 32400 470 637 350 475 520 707 425 576

1 8 1.0000 0.6060 38600 640 868 480 651 675 918 579 785

12 1.0000 0.6630 42200 700 949 530 719 735 1000 633 858

1 1/8 7 1.1250 0.7630 42300 800 1085 600 813 840 1142 714 968

12 1.1250 0.8560 47500 880 1193 660 895 925 1258 802 1087

1 1/4 7 1.2500 0.9690 53800 1120 1518 840 1139 1175 1598 1009 1368

12 1.2500 1.0730 59600 1240 1681 920 1247 1300 1768 1118 1516

1 3/8 6 1.3750 1.1550 64100 1460 1979 1100 1491 1525 2074 1322 1792

12 1.3750 1.3150 73000 1680 2278 1260 1708 1750 2380 1506 2042

1 1/2 6 1.5000 1.4050 78000 1940 2630 1460 1979 2025 2754 1755 2379

12 1.5000 1.5800 87700 2200 2983 1640 2224 2300 3128 1974 2676

Values for ZincYellow Chromate Fasteners

SAE GRADE 5 BOLTS & GRADE 2 NUTS

Torque

(Dry)

Torque

Lubricated

3. *ASSEMBLYUSES HARDENED WASHER

NOTES: 1. THESE TORQUE VALUES DONOT APPLY TO CADMIUM PLATED FASTENERS

2. ALL TORQUEVALUESARE STATICTORQUE MEASUREDPER STANDARD AUDIT METHODS TOLERANCE= ±10%

MY4510J

JLG P/N Loctite® P/N

ND Industries P/N

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

2.2.1 SAE Fastener Torque Chart

General Information and Specifications

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-3

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

In Sq In

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318

28 0.2500 0.0364

In Sq In

5/16 18 0.3125 0.0524

24 0.3125 0.0580

3/8 16 0.3750 0.0775

24 0.3750 0.0878

7/16 14 0.4375 0.1063

20 0.4375 0.1187

1/2 13 0.5000 0.1419

20 0.5000 0.1599

9/16 12 0.5625 0.1820

18 0.5625 0.2030

5/8 11 0.6250 0.2260

18 0.6250 0.2560

3/4 10 0.7500 0.3340

16 0.7500 0.3730

7/8 9 0.8750 0.4620

14 0.8750 0.5090

1 8 1.0000 0.6060

12 1.0000 0.6630

1 1/8 7 1.1250 0.7630

12 1.1250 0.8560

1 1/4 7 1.2500 0.9690

12 1.2500 1.0730

1 3/8 6 1.3750 1.1550

12 1.3750 1.3150

1 1/2 6 1.5000 1.4050

12 1.5000 1.5800

Values for Zinc Yellow Chromate Fasteners

3. *ASSEMBLY USES HARDENED WASHER

NOTES: 1. THESE TORQUEVALUES DO NOTAPPLYTO CADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

1320 43 5 1580 60 7 1800 68 8 2860 143 16 129 15 3280 164 19 148 17

LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m

4720 25 35 20 25 20 25 5220 25 35 25 35 20 25 7000 45 60 40 55 35 50 7900 50 70 45 60 35 50

9550 70 95 65 90 50 70 10700 80 110 70 95 60 80 12750 105 145 95 130 80 110 14400 120 165 110 150 90 120 16400 155 210 140 190 115 155 18250 170 230 155 210 130 175 20350 210 285 190 260 160 220 23000 240 325 215 290 180 245 30100 375 510 340 460 280 380 33600 420 570 380 515 315 430 41600 605 825 545 740 455 620 45800 670 910 600 815 500 680 51500 860 1170 770 1045 645 875 59700 995 1355 895 1215 745 1015 68700 1290 1755 1160 1580 965 1310 77000 1445 1965 1300 1770 1085 1475

87200 1815 2470 1635 2225 1365 1855

96600 2015 2740 1810 2460 1510 2055

104000 2385 3245 2145 2915 1785 2430

118100 2705 3680 2435 3310 2030 2760 126500 3165 4305 2845 3870 2370 3225 142200 3555 4835 3200 4350 2665 3625

K=.18

K=0.15

SAE GRADE 8 (HEX HD) BOLTS & GRADE 8 NUTS*

Torque

(Dry orLoctite® 263)

K= 0.20

MY4660J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

2.2.1 SAE Fastener Torque Chart (Continued)

2-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 122 14 114 13

28 0.2500 0.0364 3280 139 16 131 15

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 20 25 20 25 20 25

24 0.3125 0.0580 5220 25 35 20 25 20 25

3/8 16 0.3750 0.0775 7000 35 50 35 50 35 50

24 0.3750 0.0878 7900 40 55 40 55 35 50

7/16 14 0.4375 0.1063 9550 60 80 55 75 50 70

20 0.4375 0.1187 10700 65 90 60 80 60 80

1/2 13 0.5000 0.1419 12750 90 120 85 115 80 110

20 0.5000 0.1599 14400 100 135 95 130 90 120

9/16 12 0.5625 0.1820 16400 130 175 125 170 115 155

18 0.5625 0.2030 18250 145 195 135 185 130 175

5/8 11 0.6250 0.2260 20350 180 245 170 230 160 220

18 0.6250 0.2560 23000 205 280 190 260 180 245

3/4 10 0.7500 0.3340 30100 320 435 300 410 280 380

16 0.7500 0.3730 33600 355 485 335 455 315 430

7/8 9 0.8750 0.4620 41600 515 700 485 660 455 620

14 0.8750 0.5090 45800 570 775 535 730 500 680

1 8 1.0000 0.6060 51500 730 995 685 930 645 875

12 1.0000 0.6630 59700 845 1150 795 1080 745 1015

1 1/8 7 1.1250 0.7630 68700 1095 1490 1030 1400 965 1310

12 1.1250 0.8560 77000 1225 1665 1155 1570 1085 1475

1 1/4 7 1.2500 0.9690 87200 1545 2100 1455 1980 1365 1855

12 1.2500 1.0730 96600 1710 2325 1610 2190 1510 2055

1 3/8 6 1.3750 1.1550 104000 2025 2755 1905 2590 1785 2430

12 1.3750 1.3150 118100 2300 3130 2165 2945 2030 2760

1 1/2 6 1.5000 1.4050 126500 2690 3660 2530 3440 2370 3225

12 1.5000 1.5800 142200 3020 4105 2845 3870 2665 3625

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS.IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.

SOCKET HEAD CAP SCREWS

Magni Coating*

Torque

(Dry) K = .17

K=0.16

K=0.15

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM

MY4670J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite® 242™ or 271™

Vibra-TITE™ 111 or 140

OR Precoat 85®

2.2.1 SAE Fastener Torque Chart (Continued)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-5

General Information and Specifications

Size TPI Bolt Dia

Tensile

Stress Area

Clamp Load

See Note4

In Sq In LB IN-LB [N.m] IN-LB [N.m] IN-LB [N.m]

4 40 0.1120 0.00604

48 0.1120 0.00661

6 32 0.1380 0.00909

40 0.1380 0.01015

8 32 0.1640 0.01400

36 0.1640 0.01474

10 24 0.1900 0.01750

32 0.1900 0.02000

1/4 20 0.2500 0.0318 2860 143 16 129 15

28 0.2500 0.0364 3280 164 19 148 17

In Sq In LB FT-LB [N.m] FT-LB [N.m] FT-LB [N.m]

5/16 18 0.3125 0.0524 4720 25 35 20 25 20 25

24 0.3125 0.0580 5220 25 35 25 35 20 25

3/8 16 0.3750 0.0775 7000 45 60 40 55 35 50

24 0.3750 0.0878 7900 50 70 45 60 35 50

7/16 14 0.4375 0.1063 9550 70 95 65 90 50 70

20 0.4375 0.1187 10700 80 110 70 95 60 80

1/2 13 0.5000 0.1419 12750 105 145 95 130 80 110

20 0.5000 0.1599 14400 120 165 110 150 90 120

9/16 12 0.5625 0.1820 16400 155 210 140 190 115 155

18 0.5625 0.2030 18250 170 230 155 210 130 175

5/8 11 0.6250 0.2260 20350 210 285 190 260 160 220

18 0.6250 0.2560 23000 240 325 215 290 180 245

3/4 10 0.7500 0.3340 30100 375 510 340 460 280 380

16 0.7500 0.3730 33600 420 570 380 515 315 430

7/8 9 0.8750 0.4620 41600 605 825 545 740 455 620

14 0.8750 0.5090 45800 670 910 600 815 500 680

1 8 1.0000 0.6060 51500 860 1170 775 1055 645 875

12 1.0000 0.6630 59700 995 1355 895 1215 745 1015

1 1/8 7 1.1250 0.7630 68700 1290 1755 1160 1580 965 1310

12 1.1250 0.8560 77000 1445 1965 1300 1770 1085 1475

1 1/4 7 1.2500 0.9690 87200 1815 2470 1635 2225 1365 1855

12 1.2500 1.0730 96600 2015 2740 1810 2460 1510 2055

1 3/8 6 1.3750 1.1550 104000 2385 3245 2145 2915 1785 2430

12 1.3750 1.3150 118100 2705 3680 2435 3310 2030 2760

1 1/2 6 1.5000 1.4050 126500 3165 4305 2845 3870 2370 3225

12 1.5000 1.5800 142200 3555 4835 3200 4350 2665 3625

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITYOF SHCS.IF HIGHER LOAD IS REQUIRED, ADDITIONALTESTING ISREQUIRED.

SOCKET HEAD CAP SCREWS

Torque

(Dry)

K=.20

Torque

(Loctite® 242TMor 271

OR Vibra-TITETM111 or

140 ORPrecoat 85®

K=0.18

Zinc Yellow Chromate Fasteners*

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATEDSTEEL OR RAWALUMINUM

Torque

(Loctite® 262

or Vibra-

TITE

131)

K=0.15

MY4680J

2.2.1 SAE Fastener Torque Chart (Continued)

2-6

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2.2.2 Metric Fastener Torque Chart

Size PITCH

Tensile

Stress

Area

Clamp

Load

Torque

(Dry orLoctite®

263

)

Torque

(Lub)

Sq mm KN [N.m] [N.m] [N.m] [N.m]

3 0.5 5.03 2.19 1.3 1.0 1.2 1.4

3.5 0.6 6.78 2.95 2.1 1.6 1.9 2.3 4 0.7 8.78 3.82 3.1 2.3 2.8 3.4 5 0.8 14.20 6.18 6.2 4.6 5.6 6.8 6 1 20.10 8.74 11 7.9 9.4 12 7 1 28.90 12.6 18 13 16 19 8 1.25 36.60 15.9 26 19 23 28

10 1.5 58.00 25.2 50 38 45 55 12 1.75 84.30 36.7 88 66 79 97 14 2 115 50.0 140 105 126 154

16 2 157 68.3

219 164 197 241 18 2.5 192 83.5 301 226 271 331 20 2.5 245 106.5 426 320 383 469 22 2.5 303 132.0 581 436 523 639 24 3 353 153.5 737 553 663 811 27 3 459 199.5 1080 810 970 1130 30 3.5 561 244.0 1460 1100 1320 1530 33 3.5 694 302.0 1990 1490 1790 2090 36 4 817 355.5 2560 1920 2300 2690 42 4.5 1120 487.0 4090 3070 3680 4290

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED,

ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

Values for Zinc Yellow Chromate Fasteners

CLASS 8.8 METRIC BOLTS

CLASS 8 METRIC NUTS

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

MY4690J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

General Information and Specifications

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-7

General Information and Specifications

Size PITCH

Tensile

Stress

Area

Clamp

Load

K =0.20

K= 0.18

K=0.15

Sq mm KN [N.m] [N.m] [N.m]

3 0.5 5.03 3.13

3.5 0.6 6.78 4.22 4 0.7 8.78 5.47 5 0.8 14.20 8.85 6 1 20.10 12.5 7 1 28.90 18.0 25.2 22.7 18.9 8 1.25 36.60 22.8 36.5 32.8 27.4

10 1.5 58.00 36.1 70 65 55 12 1.75 84.30 52.5 125 115 95 14 2 115 71.6 200 180 150

16 2 157 97.8

315 280 235 18 2.5 192 119.5 430 385 325 20 2.5 245 152.5 610 550 460 22 2.5 303 189.0 830 750 625 24 3 353 222.0 1065 960 800 27 3 459 286.0 1545 1390 1160 30 3.5 561 349.5 2095 1885 1575 33 3.5 694 432.5 2855 2570 2140 36 4 817 509.0 3665 3300 2750 42 4.5 1120 698.0 5865 5275 4395

Values for Zinc Yellow Chromate Fasteners

CLASS 10.9 METRIC BOLTS

CLASS 10 METRIC NUTS

CLASS 12.9 SOCKET HEAD CAP SCREWS M3 - M5*

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

MY4700J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque Dry

Loctite® 263™

Torque

Lube OR Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

2.2.2 Metric Fastener Torque Chart (Continued)

2-8

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2.2.2 Metric Fastener Torque Chart

Size PITCH

Tensile

Stress

Area

Clamp Load

See Note4

K=.17

K=.16

K=.15

Sq mm kN [N.m] [N.m] [N.m]

3 0.5 5.03

3.5 0.6 6.78 4 0.7 8.78 5 0.8 14.20 6 1 20.10 12.5 13 12 11 7 1 28.90 18.0 21 20 19 8 1.25 36.60 22.8 31 29 27

10 1.5 58.00 36.1 61 58 54 12 1.75 84.30 52.5 105 100 95 14 2 115 71.6 170 160 150

16 2 157

97.8 265 250 235 18 2.5 192 119.5 365 345 325 20 2.5 245 152.5 520 490 460 22 2.5 303 189.0 705 665 625 24 3 353 220.0 900 845 790 27 3 459 286.0 1315 1235 1160 30 3.5 561 349.5 1780 1680 1575 33 3.5 694 432.5 2425 2285 2140 36 4 817 509.0 3115 2930 2750 42 4.5 1120 698.0 4985 4690 4395

CLASS 12.9 SOCKET HEAD CAP SCREWS

M6 ANDABOVE*

4. CLAMPLOAD LISTEDFOR SHCS IS SAMEAS GRADE 8 OR CLASS 10.9 AND DOES NOT REPRESENT FULL STRENGTH CAPABILITY OF SHCS. IFHIGHER LOAD IS REQUIRED, ADDITIONAL TESTING IS REQUIRED.

*3. ASSEMBLY USES HARDENED WASHER OR FASTENER IS PLACED AGAINST PLATED

STEEL OR RAWALUMINUM

NOTES: 1.THESE TORQUE VALUESDO NOTAPPLY TOCADMIUM PLATED FASTENERS

2. ALL TORQUE VALUESARE STATICTORQUE MEASURED PER STANDARD AUDIT METHODS TOLERANCE = ±10%

Magni Coating*

MY4710J

Torque

Loctite® 262™

Vibra-TITE™ 131

Torque

Lube OR Loctite®

242™ or 271™

Vibra-TITE™

111 or 140

Torque Dry

Loctite® 263™

(Continued)

General Information and Specifications

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-9

General Information and Specifications

2.2.3 Hydraulic Hose Torque Chart

O-Ring Face Seal & JIC Torque Chart

Size ORFS JIC Flats Method

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

74 lb-ft

(100 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

13 lb-ft

(18 Nm)

23 lb-ft

(31 Nm)

40 lb-ft

(54 Nm)

60 lb-ft

(81 Nm)

85 lb-ft

(115 Nm)

115 lb-ft

(156 Nm)

170 lb-ft

(230 Nm)

200 lb-ft

(271 Nm)

1.5 to 1.75

1 to 1.5

1.5 to 1.75

1.0 to 1.5

0.75 to 1.0

Flats Method:

1. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).

2. Mark a dot on one of the swivel nut flats and another dot in line on the hex of the adapter it’s connecting to.

3. Use the double wrench method while tightening to avoid hose twist.

4. After the connection has been properly tightened, mark a straight line across the connecting parts, not covering the dots indicating that the con necti on has been properly tightened.

32 N/A

270 lb-ft

(366 Nm)

0.75 to 1.0

Note: By definition the “Flats Method“ will contain some variance. Use the “Flats Method” only when accessibility with a torque wrench is not possible.

Torque Wrench:

1. Identify the appropriate application and refer to the above chart for the correct torque value.

2. If equipped, lubricate o-ring with hydraulic oil. Hand tighten the swivel nut until no lateral movement of the swivel nut can be detected. Average hand torque is 3 lb-ft (4 Nm).

3. Use the double wrench method while tightening to avoid hose twist.

4. Torque wrench must be held at the center of the grip. Apply constant force until it clicks.

5. After the connection has been properly tightened, mark a straight line across the connecting parts indicating that the connection has been properly tightened.

2-10

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

General Information and Specifications

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

Function Speed

First Gear 5 km/h (3.1 mph) Second Gear 10 km/h (6.2 mph) Third Gear 25 km/h (15.5 mph) Fourth Gear (Turbo Only) 35 km/h (21.7 mph)

2.3.2 Hydraulic Cylinder Performance Specifications

Note: Machine with no load, engine at full throttle, hydraulic oil above 130° F (54° C) minimum, engine at operating temperature.

Function

7M 8M 9M 12M 13M 17M

Boom Extend 11,60 11,60 13,30 14,03 16,88 23,0 Boom Retract 83 9,83 11,27 12,48 15,02 18,0 Boom Lift 8,28 9,43 14,0 12,32 14,00 15,5 Boom Lower 5,63 6,41 9,65 8,49 9,65 10,0 Attachment Tilt - UP 9,78 9,78 9,78 9,78 9,78 4,5 Attachment Tilt - DOWN 4,50 4,50 4,50 4,50 4,50 9,8 Outrigger - UP N/A N/A N/A 2,93 2,93 8,7 Outrigger - DOWN N/A N/A N/A 2,19 2,19 6,4 Frame Level 11,0 11,0 11,0 11,0 11,0 N/A

Approximate Times (sec.)

2.3.3 Platform Hydraulic Performance Specifications

Function

Platform Lift 31 39 Platform Lower 31 39

Approximate Times (sec.)

13M 17M

Platform Extend 19 27 Platform Retract 19 27 Platform Rotate 180° 14 14

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-11

General Information and Specifications

2.3.4 Electrical System

Note: Refer to Section 9.6, “Fuses and Relays,” for more information.

Battery

Type, Rating 12V DC, Negative (-) Ground, Limited Maintenance,

Wet Charged

Quantity 1 (100 Ah) (C

) Reserve Capacity CCA @ -18° C: 880 EN Group/Series DIN 600,38 Alternator 12V, 85 Amps Starter 12V, 3,2 KW Type EV (Gear Reduction)

2.3.5 Engine Performance Specifications

Note: Engine manufacturer's maximum “high idle” setting is lockwired and sealed. DO NOT disturb this setting.

Description

Engine Make/Model Perkins 1004-40T Low Idle 925 RPM ±50 RPM High Idle 2340 RPM ±50 RPM Horsepower 80,4 BHP/60 KW @ 2200 rpm Fuel Delivery Fuel Injection Air Cleaner Dry Type, Replaceable Primary and Safety Elements

2.3.6 Tires

Note: Standard wheel lug nut torque is 500 Nm (369 lb-ft).

Size Tire Type Minimum Ply Fill Type Pressure

405/70-24 MPT01 AG 14 Ply Pneumatic 4,0 Bar (58 psi) 405/70-24 MPT04 CONST 14 Ply Pneumatic 4,0 Bar (58 psi) 405/70-24 MPT01 AG (4017PS only) 14 Ply Pneumatic 4,5 Bar (65 psi) 405/70-24 MPT04 CONST (4017PS only) 14 Ply Pneumatic 4,5 Bar (65 psi)

2-12

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

General Information and Specifications

2.4 FLUIDS, LUBRICANTS AND CAPACITIES

Engine Crankcase Oil

Capacity w/Filter Change 8,5 L (9 qt) Oil Type

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS

15W-40 CH

40.8 & 40.9 DF Super ENGINE OIL 15W-40

Fuel Tank

Capacity 140 L (37 gal) Type of Fuel #2 Diesel

Cooling System

System Capacity 20 L (5 gal) Type of Fluid 50/50 mix of ethylene glycol and water

Hydraulic System

System Capacity (8, 9M, 40.8 & 40.9) 220 L (58 gal) System Capacity (12, 13 & 17M) 240 L (63 gal) Reservoir Capacity to FULL Mark 160 L (42 gal)

Type of Fluid

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS

Mobilfluid 424

(ISO 46)

40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid

Transmission

Capacity with Filter Change 12,9 L (13.6 qt)

Type of Fluid

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS

Mobilfluid 424

(ISO 46)

40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid

Transfer Case

Capacity 1,4 L (1.5 qt)

Type of Fluid

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS

Mobilfluid 424

(ISO 46)

40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-13

General Information and Specifications

Axles

Differential Housing Capacity - Front 8,0 L (8.5 qt) Differential Housing Capacity - Rear 7,3 L (7.7 qt) Wheel End Capacity - Front 1,9 L (2.0 qt) Wheel End Capacity - Rear 1,4 L (1.5 qt)

Type of Fluid

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS

Mobilfluid 424

(ISO 46)

40.8 & 40.9 DF UTTO Tractor Hydraulic Fluid

Brake System

System Capacity 1,0 L (1.1 qt) Type of Oil

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS & 4017PS

Dexron II or III ATF

40.8 & 40.9 DONAX TA

Air Conditioning System (if equipped)

System Capacity 2,05 kg (4.5 lb) Type of Refrigerant R-134a Tetrafluoroethane Type of Lubricant PAG-oil SP-20, TXV System Quantity of Lubricant 68,3 ccm (2.3 oz)

2-14

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

General Information and Specifications

MZ1671

Air Filter

Check Fuel

Level

Check Engine

Oil Level

Check

Transmission

Oil Level

Check Hydraulic

Oil Level

Check Tire

Condition &

Pressure

Check Brake

Fluid Level

EVERY

Additional Checks -

Operation &

Safety Manual

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Axle Oil

Change Wheel

End Oil

Check Boom

Chain & Tension

(17M Only)

Change Engine

Oil & Filter

Change

Transmission

Oil & Filter

MZ1681

250

EVERY

Check Axle

Oil Level

Check Wheel

End Oil Levels

Air Filter

Vacuator

Valve

Check

Fan Belt

Check Boom

Chain & Tension

(17M Only)

Check Boom

Wear Pads

Check Transfer

Case Oil Level

Change Engine

Oil and

Filter

Check LSI

Calibration

500

EVERY

Check Wheel

Lug Nut

Torque

LB/FT (Nm)

Change Fuel

Filter

EVERY

Drain Fuel/

Water

Separator

Check Engine Coolant Level

Lubrication

Schedule

Check

Battery

Check Washer

Fluid Level

MZ1690

1500

EVERY

Change

Engine Coolant

Change

Hydraulic

Fluid & Filters

Change

Hydraulic Tank

Breather

Change

Brake Fluid

1000

EVERY

Change Axle Oil

Change Wheel

End Oil

Change

Transmission

Oil & Filter

Change

Transfer Case

Oil

2.5 MAINTENANCE SCHEDULES

2.5.1 8 & 1st 50 Hour Maintenance Schedule

2.5.2 50, 250 & 500 Hour Maintenance Schedule

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2.5.3 1000 & 1500 Hour Maintenance Schedule

2-15

General Information and Specifications

EVERY

OZ2260

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lubrication Schedule

8, 9, 12 & 13M

2-16

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

17M

OZ2430

EVERY

General Information and Specifications

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-17

General Information and Specifications

OZ2270

EVERY

2.6.2 50 Hour Lubrication Schedule

8, 9, 12 & 13M

2-18

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

17M

OZ2440

EVERY

General Information and Specifications

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

2-19

General Information and Specifications

This Page Intentionally Left Blank

2-20

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section 3

Boom

Contents

PARAGRAPH TITLE PAGE

3.1 Boom System Component Terminology - Two a nd Three Section Boom . . . . . 3-3

3.2 Boom System - Two and Three Section Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2.1 Boom System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3 Boom Assembly Maintenance - Two and Three Section Boom . . . . . . . . . . . . . 3-4

3.3.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3.2 Second Section Boom Removal (12 & 13M). . . . . . . . . . . . . . . . . . . . . . . 3-5

3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (8 &

9M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (8

& 9M). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.3.5 Second Section Boom Installation (12 & 13M) . . . . . . . . . . . . . . . . . . . . . 3-6

3.3.6 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.4 Boom System Component Terminology - Four Section Boom. . . . . . . . . . . . . . 3-8

3.5 Boom System - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.5.1 Boom System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6 Boom Assembly Maintenance - Four Section Boom. . . . . . . . . . . . . . . . . . . . . . 3-9

3.6.1 Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

3.6.2 Second, Third and Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . 3-10

3.6.3 Third and Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.6.4 Fourth Boom Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.6.5 Hose Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.6.6 Hose Carrier Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.6.7 Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.6.8 Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.6.9 Second, Third and Fourth Boom Section Installation . . . . . . . . . . . . . . . . 3-14

3.6.10 Boom Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

3.7 Boom Extend and Retract Chains Four Section Boom. . . . . . . . . . . . . . . . . . . . 3-18

3.7.1 Boom Chain Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7.2 Inspection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

3.7.3 Expose Chains for Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

3.7.4 Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.8 Boom Section Separation Adjustment - Four Section Boom . . . . . . . . . . . . . . . 3-21

3.9 Hose Carrier Assembly - Four Section Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.9.1 Hose Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.9.2 Hose Carrier Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-1

Boom

3.10 Boom Wear Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.10.1 Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.10.2 Wear Pad Installation and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

3.11 Quick Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

3.11.1 Connecting with a Mechanical Quick Switch Device. . . . . . . . . . . . . . . . . 3-26

3.11.2 Connecting with a Hydraulic Quick Switch Device . . . . . . . . . . . . . . . . . . 3-26

3.11.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment . . . 3-26

3.11.4 Quick Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.11.5 Quick Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.12 Forks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

3.13 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

3-2

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3.1 BOOM SYSTEM COMPONENT

MZ1480

SECOND

BOOM

SECTION

FIRST BOOM

SECTION PIVOT PIN

EXTEND/RETRACT

CYLINDER

TILT CYLINDER

ACCESS

PANEL

QUICK SWITCH

ACCESS

PANEL

QUICK SWITCH

SECOND

BOOM

SECTION

EXTEND/RETRACT

CYLINDER

PIVOT PIN

FIRST

BOOM

SECTION

THIRD

BOOM

SECTION

THREE SECTION BOOM

TWO SECTION BOOM

TILT CYLINDER

TERMINOLOGY - TWO AND THREE SECTION BOOM

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.

Boom

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-3

Boom

3.2 BOOM SYSTEM - TWO AND THREE SECTION BOOM

3.2.1 Boom System Description

The boom operates via an interchange among the electrical, hydraulic and mechanical systems. Components involved include the joystick, tilt cylinder, extend/retract cylinder, lift/lower cylinder, compensation cylinder, electronic sensors, various pivots, supporting hardware and other components.

3.3 BOOM ASSEMBLY MAINTENANCE TWO AND THREE SECTION BOOM

Note: Boom replacement must be completed in sequence, one boom section at a time these instructions.

Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understand and follow these instructions.

3.3.1 Boom Removal

1. Remove any attachment from the quick switch assembly. Refer to Section 3.11.1, “Connecting with a Mechanical Quick Switc h Devi ce .”

Note: If replacing the innermost boom section, remove the quick switch assembly. Refer to Section 3.11.4, “Quick Switch Removal.”

2. Park the machine on a hard, level surface. Be sure there is enough room in front of the machine to allow the boom sections to be removed.

3. Fully retract the boom then raise the boom to access the rod end pin of the lift/lower cylinder. Place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

4. Place a Do Not Operate Tag on both the ignition key switch and steering wheel stating that the machine should not be operated.

5. Open the engine cover. Allow the system fluids to cool.

6. Properly disconnect the battery.

7. Relieve any trapped pressure in the tilt hydraulic system by using the handle or wrench (located in the toolbox) and move the double nut on the side of the actuator module on the tilt valve section back and forth. Repeat on the auxiliary valve section and on the extend/retract section.

, as described in

8. Label, disconnect and cap hydraulic hoses attached the hose rack at the left rear corner of the boom.

9. Disconnect the boom angle indicator rod from the switch at the inside left corner of the main boom section and frame. Refer to Section 9.14.7, “Boom Angle Sensor.”

10. Support the front of the boom by placing a sling behind the boom head. Support the lift/lower cylinder and remove the lock bolt and then the rod end pin. Lower the lift/lower cylinder onto the frame rails.

11. Lower the boom to a level position and place a suitable support under the boom head. Reposition the slings to each end of the boom.

12. Remove the lock bolt and pin from the compensation cylinder on each side of the first boom section. Remove the lock bolt and pivot pin from rear of first boom section.

13. Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the side of the first boom section.

a. If the boom is going to be disassembled after

removal:

1. Set the complete boom on level ground and by repositioning the slings, turn boom over on to the top side. Set the complete boom on suitable stands to begin teardown.

Note: With the complete boom setting upside down, the other boom section(s), tilt cylinder and hoses are made more accessible.

2. Remove the access panel from the boom head.

3. Label, disconnect and cap the hoses attached to the tilt cylinder and the hose rack on the side of the first boom section.

4. Attach a sling through the rod end of the tilt cylinder. Remove the clip from the barrel end of the tilt cylinder pin. Remove the tilt cylinder pin and lift the tilt cylinder out of the boom head.

5. Remove the hose clamp inside the innermost boom section.

6. Label, disconnect and cap the hoses attached to the extend/retract cylinder at the rear of the boom.

3-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

7. Pull the extend/retract, tilt and auxiliary hoses (1) out

MZ1720

MZ1740

MZ1730

through the rear of the boom.

8. Remove the clip from the rear extend/retract cylinder pin (2).

9. On 12 & 13M machines, remove the 2 brackets that secure the extend/retract cylinder to the second boom section.

10. Use a sling around the innermost boom section to take any pressure off of the wear pads to make pad removal easier.

1 1. Use a sling to pull the remaining boom section(s) out

far enough to gain access to the rod end of the extend/retract cylinder.

12. Remove the clip from the front extend/retract cylinder pin. Pull the extend/retract cylinder (3) out through the rear of the boom.

Boom

1. With the boom sections sitting on suitable supports, use a sling around the third boom section (4) to take any pressure off of wear pads to make pad removal easier.

2. Remove the top, left and right side wear pads, backing plates and shims. Loosen the bottom wear pad bolts and remove the shims from the first boom section to gain the necessary clearance to remove the first boom section from the second boom section (5). Tag each pad, backing plate, shim and bolts from each location.

3. Pull the second and third boom sections out from the first boom section (6).

3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (8 & 9M)

3.3.2 Second S e c tion Bo o m Remova l (12 & 13M)

1. Remove the top left and right side wear pads,

2. Pull out the innermost boom section (7).

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3. Remove the remaining wear pads.

backing plates and shims. Loosen the bottom wear pad bolts and remove the shims from the innermost boom section to gain the necessary clearance to remove the last boom section (7). Tag each pad, backing plate, shim and bolts from each location.

3-5

Boom

MZ1750

MZ1730

3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (8 & 9M)

1. Install the bottom rear wear pads (8) and bolts onto the innermost boom section. Apply Loctite and torque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install top rear wear pads, backing plates and bolts (do not shim or tighten bolts).

2. Grease the inside of the next boom section on areas where the innermost boom section wear pads will slide.

3. Using a suitable sling, balance the innermost boom section and carefully slide 1 m to 1,5 m (3’ to 4’) into the front of the next boom section. Set the innermost boom section head onto suitable supports and reset sling under the boom head. Carefully slide the innermost boom section into the next section. Leave 15 cm to 20 cm (6” to 8”) of the innermost boom section out to be able to install wear pads on the front of the next boom section.

4. With the boom head still supported, install the top wear pads, washers and bolts in the front of the

larger boom section. Apply Loctite

243TM and torque to 90 Nm (66 lb-ft). Remove the boom head from supports and install the bottom wear pads, backing plates, shims and bolts in the front of the larger

boom section. Apply Loctite

243TM and torque to 90 Nm (66 lb-ft). Install both left and right side front wear pads, backing plates, shims and bolts in the front of the larger boom section. Apply Loctite and torque to 50 Nm (37 lb-ft).

243TM

Note: Shim ALL side wear pads as needed to maintain a minimum gap in the horizontal direction or a tight fit. The number of shims can vary at each shim point except on the bottom wear pads.

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly.

5. Tighten all wear pads after ensuring the minimum gap requirements have been met. Refer to Section

3.10.1, “Wear Pad Inspection.”

3.3.5 Second Section Boom Installation (12 & 13M)

1. Install the bottom rear wear pads (9) and bolts onto the second boom section. Apply Loctite torque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install top rear wear pads, backing plates and bolts (do not shim or tighten bolts).

2. Grease the inside of the first boom section on areas where the third boom section wear pads will slide.

3. Using a suitable sling, balance the first and second boom sections and carefully slide 1 m to 1,5 m (3’ to 4’) into the front of the third boom section.Set the third boom section head onto suitable supports and reset sling under the boom head. Carefully slide the first and second boom sections into the first section. Leave 15 cm to 20 cm (6” to 8”) of the second boom section out to be able to install wear pads on the front of the first boom section.

243TM and

3-6

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Boom

4. With the boom head still supported, install the top wear pads, washers and bolts in the front of the first

boom section. Apply Loctite

243TM and torque to 90 Nm (66 lb-ft). Remove the boom head from supports and install the bottom wear pads, backing plates, shims and bolts in the front of the first boom

section. Apply Loctite

243TM and torque to 90 Nm (66 lb-ft). Install both left and right side front wear pads, backing plates, shims and bolts in the front of

the first boom section. Apply Loctite

243TM and

torque to 50 Nm (37 lb-ft).

Note: Shim ALL side wear pads as needed to maintain a minimum gap in the horizontal direction or a tight fit. The number of shims can vary at each shim point except on the bottom wear pads.

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly.

5. Tighten all wear pads after ensuring the minimum gap requirements have been met. Refer to Section

3.10.1, “Wear Pad Inspection.”

3.3.6 Boom Installation

1. Insert the extend/retract cylinder through the rear of the boom. Align the extend/retract rod end with the cylinder pin mounting hole on the last boom section. Install the extend/retract cylinder pin and retaining clip.

Note: On 12 & 13M machines, install the two brackets the secure the extend/retract cylinder to the second boom section.

2. Align the extend/retract barrel end with the cylinder pin mounting hole on the first boom section. Install the extend/retract cylinder pin and retaining clip.

Note: Grease extend/retract cylinder barrel end bore and pin before installing.

8. Rebalance the boom assembly with slings, lift and carefully guide the boom into place. Align the frame pivot bore with the boom pivot bore. Install the boom

pivot pin. Ap ply L oct ite

243TM and torque to 300 Nm

(221 lb-ft).

9. With the sling still in place, install both compensation cylinders, pins and lock bolts. Apply Loctite

243TM

and torque to 120 Nm (88 lb-ft).

10. With the sling still in place, raise the boom enough to install the lift/lower pin and lock bolt. Apply Loctite

and torque to 300 Nm (221 lb-ft).

243

Note: Raising the boom up or down with the sling maybe necessary so the boom, compensation and lift/ lower cylinder bores can be aligned for easier pin installation.

Note: Grease the boom pivot bore, compensation cylinder rod ends, lift/lower rod end and pins before installing.

11. Uncap and connect the previously labeled hydraulic hoses to the hose rack on the side of the first boom section.

12. Connect the boom angle indicator rod from switch at the inside left rear corner of the main boom section and frame. Refer to Section 9.14.7, “Boom Angle Sensor,” for adjustment information.

13. Properly connect the battery.

14. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic oil level in the reservoir; add oil if required.

15. Install the access panel on the boom head.

16. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

17. Close and secure the engine cover.

3. Attach a sling through the rod end of the tilt cylinder and position the cylinder to its original mounting location. Install the tilt cylinder pins and retaining clips.

4. Insert the extend/retract, tilt and auxiliary hoses through the boom.

5. Uncap and connect the previously labeled hydraulic hoses to the appropriate locations on each cylinder.

6. Install the hose clamps inside the innermost boom section.

7. Using suitable slings, turn the boom over to its original orientation.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-7

Boom

MZ0800

MZ0810

MZ0830

EXTEND/RETRACT CYLINDER

FIRST BOOM

SECTION

AUXILIARY

QUICK

CONNECTS

TILT CYLINDER

SECOND BOOM

SECTION

THIRD BOOM

SECTION

FOURTH BOOM

SECTION

HOSE CARRIER

EXTEND CHAINS

(TWO PAIR)

BOTTOM VIEW

QUICK SWITCH ASSEMBLY

REAR VIEW

RETRACT CHAINS (THREE)

3.4 BOOM SYSTEM COMPONENT TERMINOLOGY - FOUR SECTION BOOM

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the name and location of the major assemblies of the boom system. The following illustration identifies the components that are referred to throughout this section.

3-8

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Boom

3.5 BOOM SYSTEM - FOUR SECTION BOOM

3.5.1 Boom System Operation

The four section boom consists of the first, second, third and fourth assemblies with double third and fourth section extend chains, a double third section retract chains and a single fourth section retract chain.

As the extend/retract cylinder, which is anchored at the front of the second boom section, and the rear of the first boom section begins to extend, it forces the second boom section out of the first boom section.

The first, second, third and fourth boom sections are connected by extend and retract chains. These chains are routed around sheaves on the second and third boom sections. As the second and third boom sections are forced out, the extend chain pulls the fourth boom section out of the third boom section.

As hydraulic pressure is applied to the retract port on the extend/retract cylinder, the second boom section is pulled back into the first boom section, and the retract chain pulls the third and fourth boom sections back into the second boom section.

This mechanical linkage formed by the chains and supporting hardware, extends and retracts the third and fourth boom sections at the same rate.

The first boom section does not extend or retract, but lifts and lowers via action of the lift cylinder.

3.6 BOOM ASSEMBLY MAINTENANCE FOUR SECTION BOOM

These instructions must be completed in sequence. The second, third and fourth boom sections are removed from the first boom section.The third and fourth boom sections are removed from the second boom section.The fourth boom section is removed from the third boom section.

Before beginning, conduct a visual inspection of the machine and work area, and review the task about to be undertaken. Read, understa nd and follow thes e instructions.

3.6.1 Boom Removal

1. Remove any attachment from the quick switch assembly. Refer to Section 3.11.1, “Connecting with a Mechanical Quick Switch Device.”

Note: If replacing the innermost boom section, remove the quick switch assembly. Refer to Section 3.11.4, “Quick Switch Removal.”

2. Park the machine on a firm, level surface. Be sure there is enough room in front of the machine to allow the boom sections to be removed. Fully retract the boom then raise the boom to access the rod end pin of lift cylinder. Place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

3. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

4. Open the engine cover. Allow the system fluids to cool.

5. Properly disconnect the battery.

6. Label, disconnect and cap both hoses from the Extend/Ret r ac t cyl ind er, tilt ho s es an d bot h Au xi li ar y hoses from tubes at left rear corner of first boom section. Cap all fittings to prevent dirt and debris from entering the hydraulic system.

7. Remove the Extend/Retract cylinder support at the top front of the first boom section.

8. Support the Extend/Retract cylinder and remove the clip and pin from rod end of extend/retract cylinder. Remove the clip and pin from barrel end of extend/ retract cylinder and remove the extend/retract cylinder.

9. Disconnect the boom angle indicator rod from switch at the inside left rear corner of the main boom section and frame.

10. Support the front of the boom by placing a sling behind the boom head. Support the Lift/Lower cylinder and remove the lock bolt and then the rod end pin. Lower the Lift/Lower cylinder onto the frame rails.

11. Remove the lock bolt and pin from Compensation cylinder on each side of first boom section. Remove the lock bolt and pivot pin from rear of first boom section.

12. Lower the boom to a level position and place a suitable support under the boom head. Reposition the slings to each end of the boom.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-9

Boom

MZ0740

MZ0790

13. Lift the complete boom off machine and set on level ground or supports being careful not to damage the tubes on the left side of boom.

3.6.2 Second, Third and Fourth Boom

Section Removal

1. Set the complete boom on level ground and by repositioning the slings turn boom over on to the top side. Set the complete boom (1) on suitable stands to begin tear down.

Note: With the complete boom setting upside down, the removal and replacing of each boom section, tilt cylinder, hoses, extend and retract chains and hose carrier are made much easier.

2. At the boom head attach a sling through rod end of tilt cylinder. Label, disconnect and cap both hoses from Tilt cylinder. Plug the cap all fittings to prevent dirt and debris from entering the hydraulic system. Remove the clip from barrel end of tilt cylinder pin. Remove the tilt cylinder pin and lift the Tilt cylinder out of the boomhead.

3. Use a suitable sling around the third section boom to take any pressure off of wear pads to make pad removal easier.

Note: Before removing the extend chains, measure the distance (2) between the face of the jam nut to the end of the chain clevis on all four extend chains. This measurement will be used when reassembling the boom.

4. At the bottom front of the first boom section, remove the jam nuts and nuts and washers from the two extend chain clevises. Remove clips and pins from the two clevises and remove clevis from each chain.

5. At the bottom front of the second boom section remove the jam nuts and nuts and washers from the two extend chain clevises. Remove clips and pins from the two clevises and remove clevis from each chain.

6. At the rear of the boom, label, disconnect and cap both Tilt hoses and both Auxiliary hoses from the bulkhead on the hose carrier. Cap all fittings to prevent dirt and debris from entering the hydraulic system.

7. Remove the clip and pin from both retract chain clevises that are attached to the rear of the third section boom. The pins can be removed through the access holes at the bottom left and right sides of the first section boom. Do not remove the clevises.

8. Remove the clip and pin from the retract chain clevis that is attached to the rear of the fourth boom section. Do not remove the clevis.

9. Pull the second section boom out 152 mm to 203 mm (6 in to 8 in) and remove all the wear pads from the front inside of the first section boom. Label all parts for installation.

10. Pull the third boom section out 152 mm to 203 mm (6 in to 8 in). Remove the top left and right side wear pads from the second boom section. Loosen the bottom rear wear pad bolts and remove the shims from the second boom section to gain the necessary clearance to be able to remove the second boom section from the first boom section. Label all parts for installation.

3-10

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

11. Using a sling around the front of the second boom

MZ0760

section, lift and slide the three boom sections 75% of the way out of the first boom section. Set the boom head down on a suitable support, then center the sling to be able to balance the three boom sections being removed. Carefully pull the three boom sections the remainder of the way out of the first boom section and set the three boom sections down on suitable supports.

12. Remove the clip and pin holdi ng each ret ract cha in from the inside of the first boom section. Clean and inspect chains. Replace if damaged.

13. Label, disconnect and cap the Tilt and Auxiliary hydraulic hoses from tubes at bottom front of first boom section. Plug all fittings to prevent dirt and debris from entering hydraulic system. Clean and inspect the hoses. Replace if damaged.

14. Inspect the boom and welds. Consult your local authorized service distributor if structural damage is detected.

15. Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the first boom section. Replace any item if damaged. (Refer to Section 3.7.1, “Boom Chain Inspection,” and Section 3.10.1, “Wear Pad Inspection.”)

Note: It is recommended that if any chain or hose is damaged that ALL chains or hoses are replaced.

3.6.3 Third and Fourth Boom Section

Removal

1. With the three boom sections setting on suitable supports remove bolts, keeper and pin from both sheaves on the bottom front of the second boom section. Remove sheaves. Remove all wear pads on the front inside of the second boom section. Label all parts for installati on.

2. Remove the bolts, keeper and pin from center sheave on the bottom rear of the third boom section. Remove the sheave.

3. Remove the top left and right side rear wear pads on the third boom section. Loosen the bottom rear wear pad bolts and remove the shims from the third boom section to gain the necessary clearance to remove the third boom section from the second boom section. Label all parts for installation.

Boom

4. Place a sling around the front of the third boom section. Lift and slide the two boom sections 75% of the way out of the second boom section. Set the boom head down on a suitable support, then center the sling to be able to balance the two boom sections being removed. Carefully pull the two boom sections (3) the remainder of the way out of the second boom section and set the two boom sections down on suitable supports.

5. Remove the lock bolts, keeper and pin from both sheaves at bottom rear of the second section boom. Remove the sheaves.

6. Remove the clip and pin holding retract chain from bottom front of second boom section. Clean and inspect chain. Replace if damaged.

7. Inspect the boom and welds. Consult your local aut horized se rvice distr ibutor if structural damage is detected.

8. Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the first boom section. Replace any item if damaged. (Refer to Section 3.7.1, “Boom Chain Inspection,” and Section 3.10.1, “Wear Pad Inspection.”)

Note: It is recommended that if any chain or hose is damaged that ALL chains or hoses are replaced.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-11

Boom

MZ0770

MZ2720

3.6.4 Fourth Boom Section Removal

1. With the two boom sections setting on suitable supports remove the bolts, keeper and pin from sheave on the front of the third boom section. Remove the sheaves. Remove all wear pads, from the front inside of the third boom section. Label all parts for installation.

2. Remove the top left and right side rear wear pads on the fourth boom section. Loosen the bottom rear wear pad bolts and remove the shims from the fourth boom section to gain the necessary clearance to be able to remove the fourth boom section from the third boom section. Label all parts for installation.

3. Loosen and remove the two bolts holding the rear of the hose carrier to the top of the third boom section. Lift and push rear of hose carrier into the fourth boom section.

Note: It is recommended that if any chain or hose is damaged that ALL chains or hoses are replaced.

3.6.5 Hose Carrier Removal

1. Label, disconnect and cap both auxiliary hydraulic hoses in the boom head. Cap all fittings to prevent dirt and debris from entering hydraulic system.

2. With fourth boom section setting on suitable supports loosen and remove the six bolts (three per side) on the fourth boom section.

3. Pull the hose carrier (5) halfway out of fourth boom section by hand and set on a suitable support. Place a sling around the center of the hose carrier to be able to balance the hose carrier while being removed. Carefully slide the hose carrier the remainder of the way out of the fourth boom section and set down on suitable supports.

4. Place a sling around the front of the fourth boom section (4). Lift and slide the fourth boom section 3/4 of the way out of the third boom section. Set the boom head down on a suitable support, then center the sling to be able to balance the fourth boom section being removed. Carefully pull the fourth boom section the remainder of the way out of the third boom section and set the fourth boom section down on suitable supports.

5. Remove the clip and pin holding both extend chains from bottom of third and fourth boom sections. Clean and inspect chains. Replace if damaged.

6. Inspect the boom and welds. Consult your local authorized service distributor if structural damage is detected.

7. Inspect hoses, hardware, wear pads, mounting points, chains and other components visible with the first boom section. Replace any item if damaged. (Refer to Section 3.7.1, “Boom Chain Inspection,” and Section 3.10.1, “Wear Pad Inspection.”)

3-12

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3.6.6 Hose Carrier Installation

1. Install the hose carrier into the fourth boom section. Using a suitable sling, place the sling under the center of the hose carrier and guide the front of hose carrier into the rear of the fourth boom section. Set the rear of the hose carrier on a suitable support. Remove the sling and slide the remainder of the hose carrier into the fourth boom section by hand.

2. Apply Loctite the bolts through the three holes on each side of the fourth boom section. Install the front two bolts first. Install the middle two next. Then the rear two bolts last. Torque to all six bolts to 90 Nm (66 lb-ft).

243TM to the hose carrier bolts. Install

3.6.7 Fourth Boom Section Installation

MZ0770

MZ0980

1. Apply Loctite® 243TM to the wear pad mounting bolts. Install the bottom, left right and top wear pads. Do not shim or tighten the side and top wear pad bolts at this time. Install both extend chains (6) on bottom rear of fourth boom section. Lay extend chains the length of fourth boom section.

2. Grease the inside third boom section on area’s where the fourth boom section wear pads will slide.

3. Using a suitable sling, balance the fourth boom section and carefully slide 914 mm to 1219 mm (3 ft to 4 ft) into the front of the third boom section. Set the fourth boom section head onto suitable support and reset sling under the boom head of the fourth boom section. Carefully slide the fourth boom section into the third boom section. Leave 1829 mm to 2438 mm (6 ft to 8 ft) of the fourth boom section out to be able to install wear pads in front of the third boom section.

4. With the sling still under boom head install the top wear pads. Lower the fourth boom section and install the bottom, left and right side wear pads. Do not shim or tighten bolts at this time.

Note: Grease wear pads, inside sheaves, bores and pins during assembly.

Boom

5. Apply Loctite

243TM to the sheave mounting bo lt s, Install the sheave (7), pin, lock pla te an d b ol ts at t he bottom front of the third boom section. Torque bolts to 90 Nm (66 lb-ft). Grease the sheave using the grease fitting in the pin. Spin the sheave by hand to ensure the sheave spins freely on the pin and to distribute grease evenly . Pull both extend c hains from the fourth boom section around the front and over the sheave. Install both ch ai n clev is es, pi ns an d clip s.

6. Retract the fourth boom section the remainder of the way into the third boom section and install the wear pads at the rear of third and fourth boom sections.

7. Apply Loctite

243TM to the wear pad mounting bolts and install the bottom left and right side wear pads, backing plates, shims and bolts. Shim the top wear pads on the rear of the fourth boom section. Shim the top left and right wear pads on the rear of the fourth boom section. Torque bolts to 90 Nm (66 lb-ft). Torque grease fitting bolts to 45 Nm (33 lb-ft).

3.6.8 Third and Fourth Boom Section Installation

1. At the rear of the third boom section apply Loctite®

2. Grease the inside second boom section on areas

3. Install retract chain, pin and clip to bottom front

Note: Keep the retract chain centered on bottom of the third boom sec tion w hile inst alli ng the third boo m sect ion into the second boom section.

to the wear pad mounting bolts and install the

243 bottom rear wear pads, washers and bolts. T orque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install the top rear wear pads, backing plates and bolts (front bolts are drilled and tapped for grease fittings. do not shim or tighten bolts). Install both extend chains on the bottom rear of the third boom section. Lay extend chains the length of third boom section.

where the third boom section wear pads will slide.

inside of the second boom section.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-13

Boom

MZ1000

MZ1010

MZ1140

4. Using a suitable sling, balance the third and fourth boom sections and carefully slide 914 mm-1219 mm (3 ft - 4 ft) into the front of the second boom section. Set the third and fourth boom sections onto a suitable support and reset the sling under the boom head of the fourth boom section. Carefully slide the third and fourth boom sections into the second boom section. Leave 152 mm-203 mm (6 in - 8 in) of the third boom section out to be able to install the wear pads in the front of the second boom section.

5. With the sling still under boom head, Apply Loctite

Note: Grease wear pads, inside sheaves, bores and pins during assembly.

to the wear pad mounting bolts and install the

243 top wear pads, washers and bolts in the front of the second boom section. Torque to 90 Nm (66 lb-ft). Lower the third and fourth boom section and apply

Loctite

243TM to the wear pad mounting bolts and install bottom wear pads, backing plates, shims, and the allenhead cap bolts in the front of the second boom section. Torque to 90 Nm (66 lb-ft). Install both left side and right side front wear pads, backing plates, shims and bolts in the front of the second boom section. Torque to 90 Nm (66 lb-ft).

8. Install the retract chain sheave (1), pin, keeper and bolts to bottom rear of third boom section. Apply

Loctite

243TM and torque to 90 Nm (66 lb-ft). Grease the sheaves using the grease fitting in the pin. Spin the sheaves by hand to ensure the sheaves spin freely on the pin and to distribute grease evenly.

9. Install both retract chain sheaves (2), pin, keeper and bolts to bottom rear of second boom section.

Apply Loctite

243TM and torque to 90 Nm (66 lb-ft). Grease the sheaves using the grease fitting in the pin. Spin the sheaves by hand to ensure the sheaves spin freely on the pin and to distribute grease evenly.

6. Install both sheaves (8), pins, lock plates and bolts at the bottom front of the second boom section. Apply

Loctite

243TM and torque bolts to 90 Nm (6 6 lb -ft ). Grease the sheaves using the grease fitting in the pin. Spin the sheaves by hand to ensure the sheaves spin freely on the pin and to distribute grease evenly. Pull both exten d ch ai ns f rom th e t hir d boom section around the front and over the sheaves. Install both chai n clev is es, pi ns a nd clip s (9).

7. Apply Loctite

243TM to the wear pad mounting bolts and install the bottom left and right side wear pads, backing plates, shims and bolts.Shim the top wear pads on the rear of the third boom section. Shim the top left and right wear pads on the rear of the third boom section.Torque bolts to 90 Nm (66 lb-ft). Torque grease fitting bolts to 45 Nm (33 lb-ft).

3-14

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3.6.9 Second, Third and Fourth Boom Section Installation

Note: Light lubrication of the boom wear surfaces with a factory authorized grease is recommended to keep the boom wear surfaces lubricated properly. Light lubrication of the boom wear surfaces is also recommended when the machine is stored, to help prevent rusting.

1. Apply Loctite At the rear of the second boom section, install the bottom rear wear pads, washers and bolts. T orque to 90 Nm (66 lb-ft). Install the bottom rear left and right side wear pads, backing plate and bolts (do not shim or tighten bolts). Install top rear wear pads, backing plates and bolts (front bolts are drilled and tapped for grease fittings. do not shim or tighten bolts).

243TM to the wear pad mounting bolts.

Boom

MZ1190

MZ1200

2. Grease the inside first boom section on area’s where the second boom section wear pads will slide.

3. Install the retract chains (3), pins and clips to bottom front inside of the first boom section.

4. Install both tilt hoses (4) and both auxiliary hoses (5) to the tubes mounted at the bottom front of the first boom section. Make sure both sets of hoses are run through the opening at the bottom front of the first boom section and run down the inside center of the boom section

the front of the second boom section. Torque to 90 Nm (66 lb-ft).

Note: Shim ALL side wear pads as needed to maintain a minimum gap (1.6 mm - 1/16 in) the horizontal direction or a snug fit. The number of shims can vary at each shim point.

7. Install the bottom left and right side wear pads, backing plates, shims and bolts at the rear of the second boom section.Shim the top wear pads on the rear of the second boom section. Shim the top left and right wear pads on the rear of the second boom

section. Apply Loctite

243TM and torque bolts to 90

Nm (66 lb-ft).

8. Retract the second, third and fourth boom sections the remainder of the way into the first boom section.

Note: Keep the retract chains, tilt and auxiliary hoses centered in the first boom section while installing the second boom section into the first boom section.

5. Using a suitable sling, balance the second, third and fourth boom sections and carefully slide 914 mm - 1219 mm (3 ft - 4 ft) into the front of the first boom section. Set the second, third and fourth boom sections onto a suitable support and reset sling under the boom head of the fourth boom section. Carefully slide the secon d, third and four th boom sections into the first boom section. Leave 152 mm - 203 mm (6 in - 8 in) of the second boom section out to be able to install wear pads in front of the first boom section.

6. With sling still under boom head, Apply Lo ct it e

243TM to the wear pad mounting bolts. Install the top wear pads, washers and bolts in the front of the first boom section. Torque to 90 Nm (66 lb-ft). Lower the second, third and fourth boom sections and apply

Loctite bottom wear pads, backing plates, shims, and bolts

243TM to the wear pad mounting bolts, Install

in the front of the first boom section. Torque to 90 Nm (66 lb-ft). Install both left side and right side front wear pads, backing plates, shims and bolts in

9. Attach the retract chain (6), pin and clip to the clevis at the rear of the fourth boom section.

10. Attach the retract chains (7), pins and clips to the clevises at the rear of the third boom section.

Note: Installing the clevis pins in the third boom section can only be done when the first boom section and the second boom section access holes are aligned.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-15

Boom

MZ0790

MZ1210

11. Attach both extend chain clevises (8) through the holes in the bottom front of the first boom section. Install the washers, adjustment nut and jam nut to the clevises.

12. Attach both extend chain clevises (9) through the holes in the bottom front of the second boom section. Install the washers, adjustment nut and jam nut to the clevises.

Note: Grease Tilt cylinder barrel end bore and pin before installing.

17. Using suitable slings, lift complete boom off supports and set on level ground. It will be necessary to place a block under the rear of the boom to keep the tilt and auxiliary tubes from being damaged

18. Turn the boom over being careful not to damage the Tilt and Auxiliary tubes mounted on the side and rear of boom.

19. After boom is turned upright, place a suitable support under the rear of the boom.

20. Attach a sling around a balance point on the Extend/ Retract cylinder and carefully set on top of the first boom section.

Note: Grease Extend/Retract cylinder barrel end bore and rod end bore and pins before installing.

Note: Adjust all four extend chains using the measurement taken in the beginning of the tear down procedure. Depending on the extent of the parts being replaced, the above measurement is to be used as a starting point ONLY.

13. Pull the rear of the hose carrier over the rear of the fourth boom section and set onto the rear of the third boom section. Using the two bolts, washers and nuts, bolt the rear of the hose carrier to the rear of

the third boom section. Apply Loctite

243TM and

torque the two bolts to 90 Nm (66 lb-ft).

14. Remove the caps from the fittings on the hose carrier bulkhead and the plugs from the tilt and auxiliary hoses. Install all four hoses and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

15. Remove the caps from the Auxiliary hoses in the boomhead and install the Auxiliary hoses from the front of the hose carrier to the Auxiliary bulkhead. Tighten each hose wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats. Bolt the auxiliary hose bulkhead to the side of the boom head and torque the two bolts to 90 Nm (66 lb-ft).

16. Using a suitable sling through the rod end of the Tilt cylinder, lower the Tilt cylinder into boomhead. Align the Tilt cylinder barrel end bore with the boomhead bore and install the Tilt cylinder pin and retaining clip.

21. Align the Extend/Retract cylinder barrel end with bore at rear of the first boom section. Install the pin and retaining clip (1).

22. Align the Extend/Retract cylinder rod end with bore at front of the second boom section. Install the pin and retaining clip (2).

23. Install Extend/Retract cylinder support (3). Apply

Loctite

243TM and torque bolts to 90 Nm (66 lb-ft).

3-16

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Boom

MZ1230

MZ1240

MZ1250

3.6.10 Boom Installation

1. Park the machine on a hard, level surface. Make sure park brake is set, key is removed from the ignition and “Do Not Operate” tag is placed in clear view in the cab.

Note: Grease the boom pivot bore, compensation cylinder rod ends, lift/lower cylinder rod end and pins before installing.

5. Remove the caps from Extend/Retract cylinder

2. Using suitable slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bore with the boom assembly pivot bore.

Install boom pivot pin (4). Apply Loctite

243TM and

torque lock bolt to 90 Nm (66 lb-ft).

3. With the sling still in place, install both Compensation cylinders, pins and lock bolts (5).

Apply Loctite

243TM and torque to 90 Nm (66 lb-ft).

fittings and plugs from Extend/Ret ra ct cy li nde r hoses. Attach each hose to the Extend/Retract cylinder fittings (7) and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1-1/2 flats.

6. Remove the caps from both Tilt tubes (8) and Auxiliary tubes (9) and plugs from both Tilt hoses and both Auxiliary hoses. Attach both sets of hoses to the Tilt tubes and the Auxiliary tubes and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1-1/2 flats.

7. Connect the boom angle indicator rod from switch at the inside left rear corner of the main boom section and frame. Refer to Section 9.14.7, “Boom Angle Sensor,” for adjustment information.

4. With the sling still in place, install the rod end of the Lift/Lower cylinder, pin and lock bolt (6). Apply

Loctite

243TM and torque to 90 Nm (66 lb-ft).

8. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic oil level in the reservoir; add oil if required.

9. Clean up all debris, hydraulic oil, etc., in, on, near and around the machine.

Note: Raising the boom up or down with the sling maybe necessary so the boom, Compensation and Lift/ Lower cylinder bores can be aligned for easier pin installation.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-17

Boom

3.7 BOOM EXTEND AND RETRACT

CHAINS FOUR SECTION BOOM

3.7.1 Boom Chain Inspection

WARNING

Worn pins, stretched or cracked links or corrosive environments can c ause ch ain failu re. A ch ain failu re could result in uncontrolled boom move ment, loss of load or machine instability.

Under normal operating conditions the boom chains will need to be inspected every 250 hours of operation. The retract chains need to be exposed and inspected every 1000 hours of operation. Refer to the Service Manual for the proper procedure. Environmental conditions and dynamic impulse/shock loads can drastically affect normal operating conditions and require more frequent inspection intervals.

Environments in which material handling vehicles operate can vary widely from outdoor moisture to temperature to mildly corrosiv e or highl y corr os ive industrial atmospheres, in addition to abrasive exposures such as sand and grit. Some effects can be as follows:

• Moisture - Corrosive rusting reduces chain strength by pitting and cracking.

• Temperature - Low temperature reduces chain strength by embrittlement. Going in and out of cold storage results in moisture from condensation.

• Chemical Solutions or Vapors - Corrosive attack on the chain components and/or the mechanical connections between the chain components. Cracking can be (and often is) microscopic. Going from microscopic cracking to complete failure can be either abrupt or may require an extended period of time.

• Abrasives - Accelerated wearing and scoring of the articulating members of the chain (pins and plates), with a corresponding reduction in chain strength. Due to the inaccessibility of the bearing surfaces (pin surfaces and plate apertures), wear and scoring are not readily noticeable to the naked eye.

Following are some examples of dynamic shock loading which can impose abnormal loads above the endurance limit of a leaf chain.

• High velocity movement of load, followed by sudden, abrupt stops.

• Carrying loads in suspension over irregular surfaces such as railroad tracks, potholes, and rough terrain.

• Attempting to “inch” loads which are beyond the rated capacity of the vehicle.

The above load cycles and environmental conditions make it impossible to predict chain life. It is therefore necessary to conduct frequent inspections until replacement life can be predicted.

The boom chain’s normal life expectancy can be expressed as a maximum percent of elongation. This is generally 3%. As the chain flexes back and forth over the sheave, the bearing joints (pins and inside link plates) gradually incur wear due to articulatio

3.7.2 Inspection Guidelines

1. Park the machine on a firm, level surface, raise the boom to a horizontal (level) position, place the transmission control lever in (N) NEUTRAL, engage the park br ake switch.

2. Fully extend the boom until the extend chain is taut. Shut the engine off.

3. The extend chains will be visible for inspection with the vehicle in this state.

4. While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

5. Inspect the retract chains every 1000 hours of operation. Refer to the Service Manual for proper procedure.

6. Inspect the chains for the following conditions:

Edge Wear

Check the chain for wear on the link plate edges caused by running back and forth over the sheave. The maximum reduction of material should not exceed 5%. This can be compared to a normal link plate height by measuring a portion of chain that does not run over the sheave.

3-18

a. Extend Chains (fourth to third section)

The extend chains between the fourth and third boom sections measures 18 mm (.713 in) (1). If the measurement of the worn chain is less than 17 mm (.677 in) (2), the chain should be replaced.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

b. Extend Chains (third to second section)

MZ1463

MZ1464

MZ1465

6 7

The extend chains between the third and second boom sections measures 29,6 mm (1.2 in) (1). If the measurement of the worn chain is less than 28,6 mm (1.1 in) (2), the chain should be replaced.

Elongation

Boom

It is important to measure the chain in the section that moves over the sheaves because it receives the most frequent articulation. Measuring the chain near its clevis terminals could give an inaccurate reading. The ends of the chains, near the clevis terminal, will not have flexed as frequently, if at all, as nearer the middle of the chains.

a. Extend Chains (fourth to third section)

When the original length (3) of 305 mm (12.00 in) per foot of extend chain between the fourth and third boom sections has elongated from wear to a length (4) of 313 mm (12.36 in), the chain should be discarded and replaced.

Measure across a span of 16 pins at the center of the extend chain. Measure from pin center to pin center. Because the retract chain is inside the boom you will not be able to measure the chain.

The maximum measurement allowed is 313 mm(12.36 in). If the measurement is more than 313 mm (12.36 in), the chain should be replaced.

b. Extend Chains (third to second section)

When the original length (3) of 317 mm (12.5 in) per foot of extend chain between the third and second boom sections has elongated from wear to a length (4) of 325 mm (12.8 in), the chain should be discarded and replaced.

Measure across a span of 10 pins at the center of the extend chain. Measure from pin center to pin center. Because the retract chain is inside the boom you will not be able to measure the chain.

The maximum measurement allowed is 325 mm(12.8 in). If the measurement is more than 325 mm (12.8 in), the chain should be replaced.

Turning or Protruding Pins

Highly loaded chain, operating with inadequate lubrication can generate abnormal frictional forces between pin and link plates. When chain is allowed to operate in this condition, a pin or series of pins, can begin to twist out of a chain, resulting in failure.

Examine the pin head rivets to determine if the “VEE” flats are still in correct alignment (5). Chain with rotated/displaced heads (6) or abnormal pin protrusion (7) should be replaced immediately.

DO NOT attempt to repair the chain by welding or driving the pin(s) back into the chain. Once the press fit integrity between outside plates and pins has been altered, it cannot be restored.

Any wear pattern on the pin heads or the sides of the link plates indicates misalignment in the system. This condition damages the chain as well as increases frictional loading and should be corrected.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-19

Boom

MZ1466

MZ1467

MZ1468

MZ1469

MZ1470

MZ1471

Distorted or Battered Link Plates

Distorted or battered link plates (8) on a leaf chain can cause tight joints and prevent flexing.

Cracked Plates

Inspect the chains very carefully, front and back as well as side to side, for any evidence of cracked plates. If any one crack is discovered, the chain should be replaced in its entirety.

It is important, however to determine the cause of the crack before installing a new chain so the condition does not repeat itself.

The types of cracks are:

• Fatigue Cracking Fatigue cracks (9) are a result of repeated cyclic loading beyond the chain’s endurance limit.

• Stress Corrosion Cracking - The

outside link plates are particularly susceptible to stress corrosion cracking (10).

• Corrosion Fatigue Cracking - Corrosion fatigue cracks are very similar to fatigue cracks in appearance. Corrosion fatigue is the combined action of an aggressive environment and cyclic stress.

Other Modes of Failure

• Tight Joints

- All joints in the chain should flex freely. Tight joints (3) resist flexing. If the problem is caused by dirt or foreign substance packed in the joints, clean and lubricate thoroughly before re-installing the chain. If the problem is caused by corrosion and rust or bent pins, replace the chain.

3.7.3 Expose Chains for Inspection

c. Extend Chains

1. Park the machine on a firm, level surface. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch and raise the boom to a horizontal (level) position.

2. Lower both outriggers completely

3. Fully extend the boom until both extend chains are taut. Shut the engine OFF.

The extend chains will be visible for inspection with the machine in this state.

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

If during the inspection, any chain is found to be damaged or stretched, the chain must recommended that when any chain is replac ed, that all the chains and clevises be replaced at the same time.

d. Retract Chains

The three retract chains are only partially visible through the rear of the boom with all the sections retracted. It is possible to see a section of the retract chain as the boom is slowly extended. If there is ANY question that one or all the retract chains are damaged, the boom should be removed and disassembled with the retract chains being inspected and replaced if necessary.

be replaced. It is

• Ultimate Strength Failure These types of failures are caused by overloads far in excess of the design load. Either fractured plates (1) or

Note: DO NOT attempt to repair a chain. Replace a stretched or damaged chain with a new part. Always replace both the chain and the clevis. It is recommended that when any chain is replaced, that all chains and clevis’ be replaced at the same time.

enlarged holes (2) can occur. If either of these failures occurs, the chain should be replaced immediately.

3-20

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Boom

797mm

31.378”

499mm

19.645”

229mm

9.016”

37mm

1.45”

20mm

.787”

e. Removing Extend and Retract Chains

The four extend chains and the three retract chains can only be removed during a complete boom teardown.

While doing the chain inspection, check all chain clevis ends for distortion or cracking and sheaves for bearing wear or grooving from the chain.

If during the inspection, any chain is found to be damaged or stretched, the chain must

be replaced. It is recommended that when any chain is replaced, that all the chains and clevis’ be replaced at the same time.

3.7.4 Chain Lubrication

After inspection and before being returned to service, chains must be lubricated with Mystik Tetrimoly Grease.

The lubricant must penetrate the chain joint to prevent wear. Applying lubricant to the external surfaces will prevent rust, but the chains should be articulated to make sure the lubricant penetrates to the working surfaces between the pins and links.

To prepare the chain for lubrication, the chain plates should be brushed with a stiff brush or wire brush to clear the space between the plates so that lubricant can penetrate to the working surfaces.

Lubricant may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded with lubricant and the boom should be extended and retracted to be sure that the lubricant penetrates to the working surfaces. All surplus lubricant should be wiped away from the external surfaces. DO NOT use a solvent for this wiping operation.

Regular application of lubricant is necessary to make sure that all working surfaces are adequately lubricated. In extremely dusty conditions, it may be necessary to lubricate the chains more often. Refer to Section 2.5, “Maintenance Schedules,” and Section 2.6, “Lubrication Schedules,” for detailed information.

Lubrication of chains on vehicles working consistently in extreme hot or cold conditions requires special consideration. Contact the local distributor for guidance.

3.8 BOOM SECTION SEPARATION ADJUSTMENT - FOUR SECTION BOOM

The second, third and fourth boom sections are set to dimensions between each section. The first and second boom sections are connected by the extend/retract cylinder which has no adjustment.

The third and fourth boom sections can be adjusted by loosening or tightening the extend chains and the retract chains.

1. Fully retract the boom and raise the boom to a horizontal position. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

2. Measure the distance between the boom sections. If adjustments are needed, extend the boom out 0,91 m to 1,2 m (3 ft to 4 ft). Shut off machine.

3. Loosen the locknuts on the extend chains and the retract chains and adjust as needed.

a. To increase the separation distance: Loosen the

retract chains locknut on the rear of the third or fourth boom sections one or two turns and tighten the extend chain loc knuts on the first and second boom sections equally the same numbe r of turns. A minimum of one full thread on the clevis must protrude beyond the locknut.

b. To decrease the separation distance: Loosen the

extend chain locknuts at the front of the first or second boom sections equally one or two turns and tighten the retract chains locknut the same number of turns. A minimum of one full thread on the clevis must protrude beyond the locknut.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-21

Boom

MZ1220

120mm - 4.75in

180mm - 7in

4. Start the machine and extend and retract the boom sections two or three times. Fully retract the boom and measure the distance between the boom sections.

5. If the measurements are within the tolerance, tighten the locknuts on the chain clevises. If more adjustment is needed, repeat procedure until the proper boom section dimensions is achieved.

6. With the boom sections within the proper tole ra nce, start the machine, lower the outriggers if necessary and extend the boom to maximum extension.

7. Shut the machine off and measure the distance between the top of both extend chains and the bottom of the second and third boom sections at the center of each boom section.

8. The distance between the top of the extend chains and the bottom of the second boom section should be approximately 180 mm (7 in). The distance between the top of the extend chains and the bottom of the third boom section should be approximately 120 mm (4.75 in).

Note: If the second boom section to the third boom section separation distance cannot be achieved, contact the local JLG distributor or the JLG Service Department.

3.9 HOSE CARRIER ASSEMBLY - FOUR SECTION BOOM

3.9.1 Hose Carrier Assembly Removal

1. Remove any attachment from the quick switch assembly. (Refer to Section 3.11.1, “Connecting with a Mechanical Quick Switch Device.”)

2. Park the machine on a hard, level surface. Be sure there is enough room in front and rear of the machine to extend the boom sections and to be able to removed the hose carrier from the rear of the boom assembly.

3. Fully extend the boom and raise the boom to a horizontal position. Place the transmission control lever in (N) NEUTRAL, engage the park brake switch.

4. Retract the boom until the rear hose carrier mounting bolts on the fourth boom section are accessible through each side of the third boom section access holes. Shut off the machine and remove the bolts.

5. Start the machine and retract the boom until the middle set of hose carrier bolts on the fourth boom section are accessible through the third boom section access holes. Shut the engine OFF and remove the bolts.

6. Start the engine and retract the boom until the front set of hose carrier bolts on the fourth boom section are just in front of the front of the third boom section. Shut the engine OFF and remove the bolts.

7. Start the engine and slowly retract the boom sections completely.

8. Shut the engine OFF and place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

9. Relieve any trapped pressure in the tilt hydraulic system by using the handle provided or a 9mm wrench and move the double nut on the side of the main control valve tilt section back and forth. Repeat on the auxiliary valve section.

10. Locate the two hos es att ach ed to th e ba rr el o f t he tilt cylinder inside the boomhead.

3-22

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

11. Label and remove the hoses from the elbow fittings

MZ0900

MZ0920

on the tilt cylinder (1). Plug the hose ends and cap the elbow fittings on the tilt cylinder to prevent dirt and debris from entering the hydraulic system.

12. Label and remove the two auxiliary hydraulic hoses (2) from the bulkhead fittings inside the boomhead. Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system.

13. At the rear of the boom, label and remove the tilt cylinder hoses and the auxiliary hoses from the hose carrier bulkhead. Plug the hose ends and cap the bulkhead fittings to prevent dirt and debris from entering the hydraulic system.

Boom

15. Remove both left and right side wear pad bolts and both left and right bottom wear pad bolts from the rear of the fourth boom section to be able to remove the hose carrier.

16. Pull the hose carrier halfway out of the rear of the boom, set on a suitable support. Using a sling around the hose carrier, balance the hose carrier and pull the remainder of the way out. Set the hose carrier on the ground or on suitable supports.

Note: If the machine or the boom has to be moved, replace all the bolts that were removed from the wear pads on the rear of the fourth boom section BEFORE the machine is started and/or the boom is retracted or extended.

3.9.2 Hose Carrier Assembly Replacement

1. Carefully lay the new hose carrier assembly out flat on a hard surface.

2. Make sure the boom is level and that the front two hose carrier holes (5) in the fourth boom section are accessible just in front of the front of the third boom section.

3. Using a sling around the center of the hose carrier, lift and carefully place the front of the hose carrier part way into the rear of the boom. Set the rear of the hose carrier down on a suitable support. Reposition the sling and lift the rear of the hose carrier and slide it the remainder of the way into the boom.

4. Apply Loctite and install both left and right side wear pads and bolts and both left and right bottom wear pads and bolts. torque the side wear pads to 50 Nm (37 lb-ft) and the bottom wear pads to 90 Nm (66 lb-ft).

243TM to the wear pad mounting bolts

14. From the top rear of the hose carrier, remove both bolts (3) holding the hose carrier (4) to the third boom section.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-23

Boom

MZ0910

MZ0920

5. Align the front two threaded holes on the hose carrier with the front two holes (5) on each side of the fourth boom section and install both bolts. Apply

Loctite

243TM and hand tighten only.

6. Fasten the rear of the hose carrier (3) to the top rear

of the third boom section. Apply Loctite

243TM and

torque both bolts to 90 Nm (66 lb-ft).

7. Start the machine and extend the boom out until the middle set of holes (6) in the fourth boom section align with access holes at the front sides of the third boom section. Shut off machine.

8. Align the middle two threaded holes on the hose carrier with the middle two holes on the fourth boom

section and install both bolts. Apply Loctite and hand tighten only.

243TM

9. Start the machine and extend the boom out until the rear set of holes (7) in the fourth boom section align with access holes on each side of the third boom section. Shut off machine.

10. Align the rear two threaded holes on the hose carrier with the rear two holes on the fourth boom section

and install both bolts. Apply Loctite

243TM and

torque to 90 Nm (66 lb-ft).

11. Torque the middle two and front two hose carrier bolts to 90 Nm (66 lb-ft).

12. Start the machine and retract the boom completely.Shut the machine off.

13. Relieve any trapped pressure in the tilt hydraulic system by using the handle provided or a 9mm wrench and move the double nut on the side of the main control valve tilt section back and forth. Repeat on the auxiliary valve section.

14. Attach both tilt cylinder hoses from the hose carrier to the tilt cylinder and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

15. Attach both auxiliary hoses from the hose carrier to the auxiliary fittings on the bulkhead and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

16. Bolt the auxiliary bulkhead onto the side of the boom

head. Apply Loctite

243TM and torque to 50 Nm

(37 lb-ft).

17. At the rear of the boom, attach both tilt cylinder hoses to the tilt hose carrier bulkhead fittings and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

18. At the rear of the boom, attach both auxiliary hoses to the auxiliary hose carrier bulkhead fittings and tighten until wrench-tight. Mark the hose fitting then tighten each hose firmly 1 to 1 1/2 flats.

19. Start the engine and operate all boom functions several times. Check for leaks, and check the hydraulic oil level in the reservoir; add oil if required.

3-24

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Boom

Ma2070

MAM1390

MY3620

3.10 BOOM WEAR PADS

The wear pads on this machine are flat rectangular wear pads with metal inserts.

A total of 13 wear pads are installed on the boom sections of the 8 & 9M machines.

A total of 26 wear pads are installed on the boom sections of the 12 & 13M machines.

A total of 50 wear pads are installed on the boom sections of the 17M machines.

3.10.1 Wear Pad Inspection

Inspect all wear pads for wear. If the angle indicators (1) on the ends of the wear pads are visible, the wear pads can be reused. If the pads show uneven wear (front to back), they should be replaced. Replace pads as a set if worn or damaged.

• The number of shims can vary at each shim point.

• The bottom wear pads must be shimmed equally on

each side.

• Maintain a total boom section clearance (5) of 1,78 - 3,30 mm (0.070 - 0.130 in) both the horizontal and vertical directions.

3.10.2 Wear Pad Installation and Lubrication

Note: Inspect all wear pads. Replace as necessary.

The following wear pad procedure must be followed to insure the proper wear pad installation:

• The wear pad inserts and mounting bolts MUST be clean from any grease, oil or other contaminates before applying Loctite mounting bolts.

• Apply Loctite

243TM to all wear pad mounting bolts.

243TM and installing

• The length of the wear pad bolt depends on the number of shims, spacers and washers being used.

• The thickness of each threaded wear pad insert is 7,92 mm (0.312 in) (A).

• The bolt length should be determined by measuring the distance from the face of the insert to the face of the boom (B) including any spacer, shim(s) and washer(s).

• Bolt thread engagement in the wear pad insert should be 6,98 ± 1,0 mm (0.275 ± 0.040 in).

• One or two hardened washers are to be used on each wear pad bolt except where noted otherwise. DO NOT use more than two hardened washers.

• Use only o ne h arde ned was her i f mo unt ing bol ts are recessed.

• Wear Pad Bolt Torque: M8x25 Bolt, 50 Nm (37 lb-ft) M8x30 Bolt, 50 Nm (37 lb-ft) M10x20 Bolt, 50 Nm (37 lb- ft) M10x22 Bolt, 50 Nm (37 lb- ft) M10x25 Bolt, 50 Nm (37 lb- ft) M10x30 Bolt, 50 Nm (37 lb- ft) M10x35 Bolt, 50 Nm (37 lb- ft) M10x40 Bolt, 50 Nm (37 lb- ft)

• A spacer (2) with holes must be used before any shim (3) is used.

• A shim (3) must be inserted between the spacer (2) and wear pad support plate, block or boom section (4).

M12x20 Bolt, 90 Nm (66 lb- ft) M12x25 Bolt, 90 Nm (66 lb- ft) M12x30 Bolt, 90 Nm (66 lb- ft) M12x35 Bolt, 90 Nm (66 lb- ft) M12x40 Bolt, 90 Nm (66 lb- ft)

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-25

Boom

MAH0980

• Torque wear pad bolts after shimming is completed.

• Lubricate the face and pockets of each wear pad

after being installed.

Boom Section Wear Pad Pathway Lubrication:

• Clean and lightly grease all wear pad pathways with Mystik Tetrimoly grease.

• Clean and lightly grease the hose carrier guide bar pathways with Mystik Tetrimoly grease.

3.11 QUICK SWITCH ASSEMBLY

This machine is equi ppe d with a qui ck sw i tch sy st em for easy attachment changes.

3.1 1.1 Connecting with a Mechanical Quick Switch Device

3.11.2 Connecting with a Hydraulic Quick Switch Device

1. Retract quick switch device to provide clearance. Check to be sure lock pin is disengaged.

2. Align attachment pin (8) with recess in attachment (9). Raise boom slightly to engage attachment pin in recess.

3. Engage quick switch device.

4. Press the button (10) and at the same time, move the joystick to engage or to disengage the quick switch device.

5. Raise the boom to eye level and visually check that the quick switch pin protrudes through the hole. If the pin does not protrude through the hole, place the attachment on the ground and return to step 2.

6. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.11.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.”

1. Retract quick switch device to provide clearance. Check to be sure lock pin (6) and retainer pin (7) is out.

2. Align attachment pin (8) with recess in attachment (9). Raise boom slightly to engage attachment pin in recess.

3. Engage quick switch device.

4. Shut off engine. Exit cab and insert lick pin and secure with retainer pin.

5. If attachment is equipped, connect auxiliary hydraulic hoses. See Section 3.11.3, “Connecting with a Quick Switch to a Hydraulic Operated Attachment.”

3.1 1.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment

1. Lower attachment to ground. Set parking brake, shut off engine and turn key back to the “ON” position.

2. Relieve pressure in the hydraulic system by actuating the joystick.

3. Connect the quick-disconnect fittings.

4. Start the engine.

3-26

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Boom

MH6460

3.11.4 Quick Switch Removal

3.12 FORKS

Forks should be cleaned and inspected prior to being attached to carriage. If the following criteria is not met, forks must be removed from service immediately.

Daily Inspection

1. Support the quick switch assembly. Remove the lock bolt (11) holding the tilt cylinder rod end pin (12) to the quick switch assembly. Remove the tilt cylinder pin.

2. Support the quick switch assembly . Remove the four bolts and covers (13) from each end of the quick switch assembly. Remove the pin from the quick switch assembly from either side.

3. Inspect the above pin for nicks or surface corrosion. Use fine emery cloth to fix minor nicks or corrosion. If damaged or if it cannot be repaired, the pin must be replaced.

3.11.5 Quick Switch Installation

1. Assemble the quick switch to the boom head. Line up the quick switch between the mounts on the boom head. The quick switch should be centered in the boom head.

2. Coat the quick switch pivot pin with an anti-seize compound. Insert the quick switch pivot pin through the quick switch and boom head. Replace the end covers and four bolts (10) to each end of the quick switch.

3. Align the quick switch with the tilt cylinder rod end and insert the tilt cylinder pin. Align the tilt cylinder pin and screw in the locking bolt (9). Torque as required.

1. Inspect forks (1) for cracks, paying special attention to heel (2) and mounting tubes (3).

2. Inspect forks for broken or bent tips (4) and twisted blades (5) and shanks (6).

Yearly Inspection

1. Straightness of the upper face of blade (5) and the front face of shank (6) should not exceed 0.5 percent of the length of blade or height of shank.

2. Angl e (7) between upper face of blade and front face of shank should not exceed 93 degrees.

3. Thickness of blade (8) and shank (9) should not be reduced to 90 percent of original thickness.

Note: Contact the local distributor with the fork part number to find the manufactured dimensions of the fork blade.

4. Ensure fork length (10) is adequate for intended loads.

5. Fork markings should be legible, re-st amp if required.

6. Compare fork tips (11) when mounted on a carriage. Maximum dif fer ence in hei ght of f ork tips is 3 perce nt of the length of the blade (10).

3-27

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Boom

3.13 TROUBLESHOOTING

This section provides an easy reference guide covering the most common problems that occur during operation of the boom.

Problem Cause Remedy

1. Boom will not extend or retract

2. Boom will not fully extend. 1. Extend/retract hydraulic system

3. Boom shifts to right or left when extending.

4. Excessive pivot pin noise and/or wear.

1. Broken hydraulic hose(s) or tube(s) and/or connections leaking.

2. Extend/retract hydraulic system not operating properly.

3. Faulty extend/retract cylinder. 3. Repair cylinder. Refer to Section

not operating properly.

1. Boom side wear pads improperly shimmed or worn.

1. Insufficient lubrication. 1. Lubricate at regular intervals.

2. Worn bearing(s). 2. Replace bearing(s) and

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8, “Hydraulic System.”

8.10.4, “Cylinder Inspection.”

1. Refer to Section 8, “Hydraulic System.”

1. Shim wear pads to correct gap. Replace wear pads as needed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication.”

Refer to Section 2.6, “Lubrication Schedules.” Replace worn pins as needed.

lubricate at regular intervals Refer to Section 2.6, “Lubrication Schedules.”

5. Boom will not raise or lower. 1. Broken hydraulic hoses or tubes and/or connection leaks .

2. Lift/lower hydraulic system not operating properly.

3. Faulty lift/lower cylinder. 3. Repair cylinder. Re fer t o Section

4. Seized boom pivot pin bearing. 4. Replace beari ng.

3-28

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

1. Locate break, replace hose(s) or tube(s), tighten connections.

2. Refer to Section 8, “Hydraulic System.”

8.10.4, “Cylinder Inspection.”

Boom

Problem Cause Remedy

6. Rapid boom pad wear. 1. Incorrect wear pad gap. 1. Check wear pad gaps and

correct as needed. Refer to Section 3.10.2, “Wear Pad Installation and Lubrication.”

7. Auxiliary hydraulics will not operate.

2. Rapid cycle times with heavy loads.

3. Contaminated, corroded or rusted wear pad sliding surfaces.

4. Operating in extremely dusty/ abrasive conditions.

1. Auxiliary hydraulic system not operating properly.

2. Reduce cycle times.

3. Remove contamin ation and/or corrosion from wear pad sliding surfaces an d lubricate. If the surfaces cannot be reconditioned, replace the boom section(s).

4. Clean equipment frequently.

1. Refer to Section 8, “Hydraulic System.”

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

3-29

Boom

This Page Intentionally Left Blank

3-30

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section 4

Cab and Covers

Contents

PARAGRAPH TITLE PAGE

4.1 Operator Cab and Covers Component Terminology . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.2.1 Serial Number Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 Cab Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.1 Steering Column and Orbitrol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.3.2 Service Brake Pedal and Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.3 Throttle Pedal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.4 Joystick Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.3.5 Parking Brake (8, 9, 12 & 13M). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3.6 Parking Brake (17M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.3.7 Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.3.8 Windshield Washer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.3.9 Heater/Defroster System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.3.10 Cab Heater/Air Conditioning Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.4 Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.5 Cab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

4-1

Cab and Covers

MZ2061

DISPLAY

PANEL

LOAD STABILITY

INDICATOR

JOYSTICK

HEATER & AC

CONTROLS

BRAKE FLUID

RESERVOIR

TRANSMISSION

CONTROL LEVER

SERVICE BRAKE

PEDAL

PARKING BRAKE

LEVER

ACCELERATOR

PEDAL

POWER/

EMERGENCY STOP SWITCH (IF EQUIPPED)

IGNITION

4.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the machine cab and covers. The following illustration identifies the components that are referred to throughout this section.

4-2

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

WARNING

MZ2000

DO NOT service the machine without following all

safety precautions as outlined in the “Safety Practices” section of this manual.

4.2 OPERATOR CAB

4.2.1 Serial Number Decal

The cab serial number decal is located inside the cab, behind the seat. Information specified on the serial number plate includes the cab model number, the cab serial number and other data. Write this information down in a convenient location to use in cab correspondence.

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

a. Orbitrol Valve Removal

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate T ag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the lower dash panel.

6. Remove the steering adjustment lever.

Cab and Covers

7. Label, disconnect and cap the hydraulic hoses attached to the steering valve (1). Cap all fittings to prevent dirt and debris from entering the hydraulic system.

8. Remove the steering wheel (2), disconnect and remove the accessory control lever (3) and transmission control lever (4).

9. Support the steering valve, and remove the four hexhead capscrews and four lockw ash ers.

10. Remove the steering assembly from the dash panel.

Note: DO NOT disassemble the orbitrol valve. The orbitrol valve is not serviceable and must be replaced in its entirety, if defective.

b. Orbitrol Valve Installation

1. Install the steering valve and steering column to their original orientation on the steering bracket with four hex-flange capscrews and four lockwashers.

2. Install the accessory control lever and transmission control lever and connect the harness connector, install the steering wheel assembly. Torque the steering wheel nut to 40 Nm (29.5 lb-ft).

Note: ALWAYS use new o-rings when servicing the machine.

3. Install new o-rings into the fittings. Lubricate the orings with clean hydraulic oil.

4. Uncap and connect the previously labeled hoses to

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

the appropriate ports.

5. Install the steering adjustment lever.

6. Properly connect the battery.

4-3

Cab and Covers

MZ1960

7. Start the engine and check the operation of steering system. Check for hydraulic oil leaks. Check the hydraulic oil level in the tank and add oil as required. Wipe up any spilled oil.

8. Install the lower dash panel.

9. Close and secure the engine cover.

10. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

c. Power Steering Test

Conduct a pressure check of the steering hydraulic circuits at the main control valve. Refer to Section 8.4.1, “Hydraulic Pressures.”

4.3.2 Service Brake Pedal and Valve

a. Service Brake Valve

Refer to Section 8.9.2, “Service Brake Valve,” for removal and installation information.

b. Service Brake Pedal Removal

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the lower dash panel.

6. Remove the circlip, flat washer, bushing and the return spring securing the service brake pedal to the cab.

7. Remove the clip/pin from the brake plunger fork link.

8. Remove the service brake pedal (5) from the cab.

c. Service Brake Pedal Installati on

1. Position the service brake pedal in its mounting location within the cab.

2. Install the brake pedal being careful to reposition th e brake plunger yoke. Install the return spring , washer, bushing and clip. Install clip/pin in brake plunger fork link.

3. Adjust the brake pedal as needed.

4. Install and secure th e low er dash cover.

5. Properly connect the battery.

6. Close and secure the engine cover.

7. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.3.3 Throttle Pedal Replacement

a. Throttle Pedal Removal

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stati ng that the machi ne should not be operated.

3. Open the engine cover. Allow the engine to cool.

4. Properly disconnect the battery.

5. Remove the lower dash panel.

4-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

6. Remove the throttle pedal return spring (6).

MZ1970

MZ2030

7. Disconnect the throttle control cable (7) from the throttle lever.

8. Remove the retaining ring from the throttle pedal pivot pin. Slide the throttle pedal, bushings and washers off the pivot pin.

9. Remove the throttle pedal assembly from the cab.

10. If a new throttle cable is required, remove the cable connector from the engine. Route the cable through the bottom of the cab and remove from the machine. Note the routing path for installation.

b. Throttle Pedal Installation

1. If required, install a new throttle cable to the engine connection and route cable to cab following the previous routing path.

2. Slide the throttle pedal, bushings and washers onto the throttle pedal pivot pin. Secure with retaining ring.

3. Connect the throttle control cable to the throttle lever.

4. Install the throttle pedal return spring.

5. Properly connect the battery.

Cab and Covers

2. From within the cab, check the engine rpm at low idle. If the rpm is not 925 ±50 rpm, readjust the throttle cable adjustments.

3. Check the engine rpm at full throttle. If the rpm is not 2340 ±50 rpm, adjust the rubber-stop screw on the throttle pedal or the throttle cable adjustments.

Note: During the full throttle check:

• DO NOT operate any hydraulic function.

• DO NOT steer or apply any pressure to the steering wheel.

• Keep the transmission in (N) NEUTRAL.

4. Close and secure the engine cover.

5. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.3.4 Joystick Assembly Replacement

a. Joystick Assembly Removal

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the engine to cool.

4. Properly disconnect the battery.

c. Throttle Adjustment

1. Adjust the distance on each end of the throttle cable from the locknut to the connector end. The distance from the connector to the locknut in the cab should be 129 mm (5 in). In the engine compartment, the distance should be 234 mm (9.2 in).

Note: These measurements are to be used as starting points. If furth er adjus tment is requi red, th e dista nce may need to be altered.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5. Remove the capscrews securing the bottom cover (8). Disconnect the electrical connections and remove the four self-tapping screws from the bottom of the joystick assembly.

6. Remove the joystick assembly (9).

4-5

Cab and Covers

MZ1490

b. Joystick Assembly Installation

1. Set the joystick assembly into the armrest support.

2. Install the four self-tapping screws. Connect the electrical connections.

3. Properly connect the battery.

4. Test the boom joystick functions:

a. Move the joystick handle rearward, activating the

boom lift function. The boom should RISE.

b. Move the joystick handle forward, activating the

boom lower function. The boom should LOWER.

c. Move the joystick handle to the right, activating

the boom extend function. The boom should EXTEND.

d. Move the joystick handle to the left, activating the

boom retract function. The boom should RETRACT.

e. Move the joystick rocker switch forward

activating the boom extend function. The boom should EXTEND.

5. Install the bottom cover.

6. Close and secure the engine cover.

7. Remove the Do Not Oper ate Tags from both the ignition key switch and the steering wheel.

4.3.5 Parking Brake (8, 9, 12 & 13M)

a. Park Brake Removal

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Block the wheels.

5. Properly disconnect the battery.

6. Remove the cover from around the park brake lever.

7. Remove the pin attached to the park brake cable (1) from the park brake lever (2).

8. Remove the bolts holding the park brake lever to the mounting plate.

9. Loosen the nuts securing the park brake cable to the mounting plate.

10. Feed the cable end through the bottom of the cab. 1 1. If necessary, remove the cable clamp from under the

cab.

Note: Record the routing of the park brake cable for later installation.

12. Remove the cable mounting hardware on the front axle to free the park brake cable.

b. Park Brake Installation

1. Install the park brake cable on the front axle.

2. Route the park brake cable using the previous routing path.

3. Feed the cable end through the bottom of the cab.

4. Secure the park brake lever to the mounting plate using the pre-existing mounting hardware.

5. Secure the park brake cable to the park brake lever with the pre-existing pin.

6. Connect the park brake electrical connector switch.

7. Properly connect the battery.

8. Test the park brake for proper functionality.

9. With the park brake applied, check the display panel for the proper indicator light.

10. Reinstall the cover around the park brake lever.

11. Unblock the wheels.

12. Close and secure the engine cover.

13. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4-6

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Cab and Covers

MZ2020

4.3.6 Parking Brake (17M)

a. Park Brake Removal

2. Place a Do Not Operate T ag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Block the wheels.

5. Properly disconnect the battery.

2. Uncap and connect the previously labeled hydraulic hoses to the park brake.

3. Connect the park brake electrical connector switch.

4. Check the routing of all hoses for sharp bends or interference with any rotating members, and install tie wraps and/or protective conduit as required.

5. Start the engine and run at approximately 30-50% throttle for about one minute, without moving the machine or operating any hydraulic functions.

6. Bleed air from the brake circuit. Refer to Section

8.9.3, “Brake Test.”

7. Inspect the park brake valve and connections for leaks, and check the level of the hydraulic oil in the reservoir. Shut the engine OFF.

8. With the park brake applied, check the display panel for the proper indicator light.

9. Wipe up any hydraulic oil spillage in, on, near and around the machine, work area and tools.

10. Reinstall the cover around the park brake lever.

11. Properly connect the battery.

12. Unblock the wheels.

13. Close and secure the engine cover.

14. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

6. Remove the cover (3) from around the park brake lever.

7. Disconnect the park brake electrical connector switch (4).

8. Label, disconnect and cap the hydraulic hoses attached to the park brake. Cap all fittings to prevent dirt and debris from entering the hydraulic system.

9. Remove the bolts holding the park brake lever to the mounting plate.

Note: DO NOT disassemble the park brake valve. The valve is not serviceable and must be replaced in its entirety, if defective.

b. Park Brake Installation

1. Secure the park brake lever to the mounting plate using the pre-existing mounting hardware.

Note: ALWAYS replace seals, o-rings, gaskets, etc., with new parts to help ensure proper sealing and operation. Lubricate seals and o-rings with clean hydraulic oil.

4.3.7 Windshield Wiper Assembly

Refer to Section 9.12.1, “Windshield Wiper Motor,” for removal and installation information.

4.3.8 Windshield Washer Assembly

Refer to Section 9.12.3, “Windshield Washer Reservoir and Pump,” for removal and installation information.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

4-7

Cab and Covers

MZ2050

MZ2040

4.3.9 Heater/Defroster System

a. Heater Assembly Removal

2. Place a Do Not Operate Tag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the belly pan.

6. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap.

7. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug and slowly remove to allow the coolant to drain. Transfer the coolant into a suitable, covered container and label as "Used Coolant". Dispose of the used coolant at an approved recycling facility. Clean and reinstall the drain plug.

10. Loosen the hose clamps and disconnect the heater hoses (6).

11. Remove the heat duct hoses (7) from the back side of the heating unit assembly.

12. Label and disconnect the electrical connectors attached to the heater assembly.

13. Remove the heater assembly mounting bolts.

14. Carefully lift the heater assembly and remove from the cab.

8. Remove the cab bottom and heater shield (5).

9. Remove the cab floor mat to gain access to the heater assembly mounting bolts.

Note: Label all hoses to ensure correct installation.

b. Heater Assembly Installation

1. Lower the heater assembly into the cab to its original orientation. Secure with the previou sl y used hardware.

2. Connect the wiring harness connections to the blower.

3. Connect the previously labeled hoses to the heater. Secure with hose clamps.

4. Fill the cooling system completely with cool ant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, “Fluids, Lubricants and Capacities.”

5. Properly connect the battery.

6. Start the engine and run at low idle. Check for any visual signs of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.

7. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.

8. Replace the cab bottom and heater shield.

4-8

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Cab and Covers

MAM0310

9. Replace the belly pan.

10. Close and secure the engine cover.

11. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.3.10 Cab Heater/Air Conditioning Controls

a. Cab Heater Controls Removal

2. Place a Do Not Operate T ag on both the ignition key switch and the steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the plastic side cover in the cab to gain access to the control cables and electronics. If necessary, remove the seat for more accessibility.

c. Installation and Testing

1. Install the control box into the dash panel until the side clips firmly hold the box.

2. Connect the previously labeled electrical connectors to the appropriate locations.

3. Connect the previously labeled control cables to the appropriate control knob mechanisms.

4. Properly connect the battery.

5. Turn the ignition key to the ON position and check the control functions.

6. Start the machine and allow engine to warm to operating temperature. Check heat control at different levels.

7. Install the plastic side cover. If necessary, install the seat.

8. Close and secure the engine cover.

9. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4.4 CAB REMOVAL

Note: To help ensure safety and optimum performance, replace the cab if it is damaged. Refer to the appropriate parts manual for ordering information.

6. Label and disconnect the control cables (8) attached to the control knob mechanisms.

7. Label and disconnect the electrical connectors attached to the control box.

8. Depress the side clips (9) and push the control box through the dash panel.

b. Disassembly DO NOT disassemble the cab heater and fan controls.

The controls are not serviceable. Replace controls if found to be defective.

Before performing any inspection, maintenance or service operation, thoroughly clean the machine. DO NOT spray water or cleaning solution in, on, near or around the operator dash panels and electrical components.

Inspect the cab, its welds and mounts. If modification, damage, a cracked weld and/or fatigued metal is discovered, replace the cab. Contact your local aut hor ized service distributor with any questions about the suitability or condition of a cab.

Note: Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses. Transfer cab parts to the replacement cab after the replacement cab is securely mounted on the machine.

1. Park the machine on a firm, level surface, level the machine. Allow sufficient overhead and side clearance for cab removal. Fully retract the boom, lower the bo om, plac e the tr an smi ssion contr ol lever in (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Block the wheels.

3. Open the engine cover. Allow the system fluids to cool.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

4-9

Cab and Covers

MZ0660

MZ0640

4. Properly disconnect the battery.

5. Remove the belly pan.

6. Drain the engine radiator. Refer to Section 7.4.3, “Radiator/Oil Cooler and Coolant Heater Replacement.”

7. Working under the cab, remove the cab bottom shield.

8. Label, disconnect and cap the heater hoses.

9. Remove the lens-head screws in the cab and remove the console panel below the right side window to access the wire harness connections, the right rear side panel and the left rear cup holder panel to access the two rear cab mount bolts. Also remove the rubber floor mat to access the front two cab mount bolts.

10. Disconnect the cab-to-wiring harness connectors at the circuit board. Push the harness connect or s through the opening at the right front corner of the cab.

11. 8, 9, 12 & 13M machines: Remove the park brake cover. Disconnect the park brake switch connector and park brake cable.

17M machines: Remove the park brake cover. Label, disconnect and cap the hydraulic hoses attached to the park brake lever. Cap all fittings to keep dirt and debris from entering the hydraulic system. Disconnect the park brake switch.

12. Working under the cab, label, disconnect and cap the hydraulic hoses at the cab fittings. Plug the hoses and cap the fittings.

13. Disconnect the throttle cable from the throttle pedal lever. Push the throttle cable through the bottom of the cab.

14. Install two lifting eye bolts with a suitable lifting capacity in the existing threaded holes (1) at the top corners of the windshield.

15. Secure the cab with a hoist or overhead crane and sling. Do not lift the cab at this time.

4-10

16. Remove the four cab-to-frame bolts (2), flat washers and nuts.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Cab and Covers

17. Remove the mirrors and all other cab components as needed, if not previously removed.

18. Use a hoist or overhead crane and sling attached to the cab, carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.

19. When all wiring, hydraulic hoses and fasteners are disconnected or removed, carefully and slowly lift the cab and remove it from the frame.

20. When the cab is completely clear of the machine, carefully lower it to the ground. Block up or support the cab so that it does not move or fall over. Assure that no personnel enter the cab while it is being removed from the machine.

21. Inspect the condition of the fittings, clamps, hydraulic hoses, etc. Replace parts as indicated by their condition.

22. Inspect and replace other machine parts that are exposed with the cab removed. Repair or replace as required.

4.5 CAB INSTALLATION

1. Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for cab installation.

2. Attach a sling with suitable lifting capacity through the previously installed eye bolts on top of the cab.

3. Using a hoist or overhead crane and sling attached to the two lifting eyes, carefully begin to align the cab with the mounting holes in the frame. Stop and check that wiring, hydraulic hoses, cables, etc., will not be pinched or damaged as the cab is positioned. Readjust the position of the sling as needed to help balance the cab during installation.

4. Install the four bolts through the cab/frame mounts and install the four washers and nuts. Remove the sling and both lifting eye bolts. Tighten and torque the four mounting bolts to 150 Nm (110 lb-ft).

5. Uncap and connect the previously labeled heater hoses to the heater assembly.

6. Uncap and connect the previously labeled air conditioner lines (if equipped) to the heater assembly.

7. 8, 9, 12, & 13M machines: Route the park brake cable back in to th e cab. S ecur e the pa rk br ake c able to the park brake lever with the pre-existing pin. Connect the previously labele d elec tric al connec tor to the park brake lever.

17M machines: Route the park brake hydraulic hoses back into the cab. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations. Connect the previously labeled electrical connector to the park brake lever.

8. Connect the throttle cable to the throttle pedal lever. Adjust the throttle as required.

9. Route any hydraulic hoses through the opening at the right front corner of the cab.

10. Uncap and connect the previously labeled hydraulic hoses to their appropriate locations.

11. Connect the previously labeled windshield wiper fluid lines to the appropriate locations.

12. Route the wiring harness connectors through the opening at the right front corner of the cab and up into the side console.

13. Connect the previously labeled cab-to-wiring harness connectors.

14. Install the right side console panel, the right rear side panel, the left rear cup holder panel and the rubber floor mat.

15. Fill the cooling system completely with coolant, allowing time for the coolant to fill the engine block. The cooling system capacity is listed in Section 2.4, “Fluids, Lubricants and Capacities.”

16. Properly connect the battery.

17. Start the engine and check the operation of all controls. Check for hydraulic leaks. Check the hydraulic oil level in the tank and add oil as required.

Note: When the engine is initially started, run it briefly at low idle and check the machine for any visual sign of fluid leakage. STOP the engine immediately if any leakage is noted, and make any necessary repairs before continuing.

18. Wait for the engine to cool and check the coolant level. Add coolant to the overflow bottle as required to bring the coolant to the proper level.

19. Reinstall engine belly pan.

20. Reinstall the cab bottom shield.

21. Close and secure the engine cover.

22. Unblock the wheels.

23. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

4-11

Cab and Covers

This Page Intentionally Left Blank

4-12

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section 5

Axles, Drive Shafts, Wheels and Tires

Contents

PARAGRAPH TITLE PAGE

5.1 Axle, Drive Shaft and Wheel Component Terminology. . . . . . . . . . . . . . . . . . . . 5-2

5.2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.1 Axle Serial Number Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.2 Axle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.3 Axle Internal Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.4 Axle Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3.5 Axle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3.6 Axle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.3.7 Axle Assembly and Drive Shaft T roubleshooting . . . . . . . . . . . . . . . . . . . 5-6

5.4 Drive Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4.1 Drive Shaft Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4.2 Drive Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4.3 Drive Shaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4.4 Drive Shaft Cleaning and Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.4.5 Drive Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.5 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.5.1 Removing Wheel and Tire Assembly from Machine. . . . . . . . . . . . . . . . . 5-10

5.5.2 Installing Wheel and Tire Assembly onto Machine. . . . . . . . . . . . . . . . . . 5-11

5.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.6.1 Brake Disk Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5.7 Towing A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7.1 Towing (8, 9, 12 & 13M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7.2 Manually Releasing the Park Brake (17M). . . . . . . . . . . . . . . . . . . . . . . . 5-12

5.7.3 Manually Resetting the Park Brake (17M) . . . . . . . . . . . . . . . . . . . . . . . . 5-12

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5-1

Axles, Drive Shafts, Wheels and Tires

MZ1510

REAR AXLE

ASSEMBLY

STEERING CYLINDER

(FRONT)

FRONT

AXLE

ASSEMBLY

STEERING CYLINDER

(REAR)

DRIVE SHAFTS

TRANSMISSION

DROP BOX

5.1 AXLE, DRIVE SHAFT AND WHEEL COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the axles, drive shafts, wheels and tires. The following illustration identifies the components that are referred to throughout this section.

5-2

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Axles, Drive Shafts, Wheels and Tires

5.2 GENERAL INFORMATION

Note: To help ensure optimum performance, the drive shaft assemblies are specially balanced as a unit at the factory. When servicing any flange yoke, slip yoke or drive shaft tube, order a complete assembly if components are bent of damaged. Refer to the appropriate parts manual for ordering information.

Before performing any inspection, maintenance or service operation, thoroughly clean the unit. The axles and drive shafts should be checked and repaired only by experienced service technicians who are aware of all safety instructions and particular component features.

Use suitable products to thoroughly clean all disassembled mechanical parts to help prevent personal injury to the worker and prevent damage to the parts. Carefully inspect the integrity of all moving parts (bearings, yokes, tubes, gears, shafts, etc.) and fasteners (nuts, bolts, washers, etc.) as they are subject to major stress and wear. Always replace elastic locknuts and any damaged, worn, cracked, seiz ed or otherw is e improp er parts that could affect the safe and proper functioning of the machine, axles and drive shafts.

5.3 AXLE ASSEMBLIES

5.3.1 Axle Serial Number Plate

The front and rear axle serial number plate is located on a mounting pad on the front side of the center section of each axle. Information on the serial number plate is required in correspondence regarding the axle.

Supply information from the axle serial number plate when communicating about an axle assembly or axle components.

5.3.2 Axle Specifications

General axle specifications are found in Section 2.4, “Fluids, Lubricants and Capacities.”

5.3.3 Axle Internal Service

Detailed axle service instructions (covering the axle, differential, brakes and wheel-end safety, repair, disassembly, reassembly, adjustment and troubleshooting information) are provided in the Dana Spicer Maintenance and Repair Manual (P/N 31200162).

WARNING

DO NOT service the machine without following all

safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

5.3.4 Axle Maintenance

CLEANING: Clean parts with machined or ground

surfaces (such as gears, bearings and shafts) with emulsion cleaners or petroleum-based cleaners. DO NOT steam clean internal components and the interior of the planetary hub and axle housing. Water can cause corrosion of critical parts. Rust contamination in the lubricant ca n cause gear and bearing failure. Remove old gasket material from all surfaces.

DRYING: Use clean, lintless towels to dry components after cleaning. DO NOT dry bearings by spinning them with compressed air; this can damage mating surfaces due to lack of lubrication. After drying, lightly coat components with oil or a rust-preventive chemical to help protect them from corrosion. If sto rin g co mp on ents f or a prolonged period, wrap them in wax paper.

PERIODIC OPERATION REQUIREMENT: Every two weeks, drive the machine far enough to cause the drivetrain components to make several complete revolutions. This will help ensure that internal components receive lubrication to minimize deterioration caused by environmental factors such as high humidity.

SUBMERSION: If the machine has been exposed to water deep enough to cover the hubs, disassemble the wheel ends and inspect for water damage and contamination. If the carrier housing was submerged in water, especially if the water level was above the vent tube (breather), drain the axle and inspect internal parts for water damage and contamination. Before assembling and refilling the unit with the specified lubricant(s), clean, examine and replace damaged parts as necess ar y.

Note: Use a suitable puller for bearing removal. Clean, inspect and lubricate all bearings just prior to reassembly. If replacement of a damaged bearing cup or cone is necessary, replace the cup and cone as a set.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5-3

Axles, Drive Shafts, Wheels and Tires

MZ1030

MZ1520

5.3.5 Axle Removal

The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and a limited-slip feature; the rear axle has neither. The follo wing steps outline a typical a xle remov al procedure, suitable for either the front or the rear axle assembly.

Cleanliness is extremely important. Before attempting to remove the axle, thoroughly clean the machi ne . Avoi d spraying water or cleaning solution on the outrigger solenoids and other electrical components. If using a steam cleaner, seal all openings before steam cleaning.

Note: Clear the work area of all debris, unnecessary personnel, etc. Allow sufficient space to raise the machine and to remove the axle.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Remove the fender assemblies.

allow the axle oil to drain into the receptacle. Transfer the used axle oil into a suitable covered container, and label the container as "Used Oil". Dispose of used oil at an approved recycling facility.

7. Label, disconnect and cap the steering and brake lines at the axle. Wipe up any spilled oil.

8. Block the front and rear of both tires on the axle that is not being removed. Ensure that the machine wil l remain in place during axle removal before proceeding.

9. Raise the machine using a suitable jack or hoist. Place suitable supports under both sides of the frame and lower the machine onto the supports. Ensure that the machine will remain in place during axle removal.

10. Support the axle that is being removed with a suitable jack, hoist or overhead crane and sling. DO NOT raise the axle or the machine.

11. Mark and remove both wheel and tire assemblies from the axle that is being removed. Refer to Section

5.5.1, “Removing Wheel and Tire Assembly from Machine.”

12. Remove the drive shaft assembly. Refer to Section

5.4.3, “Drive Shaft Removal.”

13. On the front axle, remove the hardware securing the frame level cylinder or bar. Tap the mount pin out, and move the cylinder or bar to prevent it from interfering with axle removal.

14. Remove the park brake cable from the front axle (8, 9, 12 & 13M only).

15. Remove the bolts and locknuts securing the axle to the frame.

16. Remove the axles from the machine using the jack, hoist or overhead crane and sling supporting the axle. DO NOT raise or otherwise disturb the machine while removing the axl e. Bal an ce the axle and prevent it from tipping, turning or falling while removing it from beneath the machine. Place the axle on a suitable support or holding stand.

6. If the axle will be disassembled after removal, place a suitable receptacle under the axle (1) and wheel hubs drain plugs (2). Remove the drain plugs and

5-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5.3.6 Axle Installation

The front and rear axle assemblies differ in that the front axle assembly is equipped with a parking brake mechanism and limited-slip feature; the rear axle has neither. The steps below outline a typical axle installation procedure, suitabl e for eit her the fr ont or the rear ax le assembly.

1. Before proceeding, ensure that the machine will remain in place during axle installation. Block the

Axles, Drive Shafts, Wheels and Tires

MZ1030

MZ5820

front and rear of both tires on the axle that is already installed on the machine.

2. If applicable, raise the machine using a suitable jack or hoist. Place suitable supports beneath the frame and lower the machine onto the supports, allowing enough room for axle installation. Ensure that the machine will remain in place during axle installation.

3. Using a suitable jack, hoist or overhead crane and sling, remove the axle from its support or holding stand. Balance the axle and prevent it from tipping, turning or falling while positioning it beneath the machine. DO NOT raise or otherwise disturb the machine while installing the axle. Keep the axle supported and balanced on the jack, hoist or overhead crane and sling throughout the installation procedure.

4. Position the axle under the frame, and align the axle housing with the holes in the frame.

5. Install the axle bolts and nuts. Tighten and torque the axle nuts to 550-600 Nm (406-443 lb-ft).

6. Move the cylinder or bar into position on the front axle anchor ( if necessary). Install the mount pin.

7. Apply a multi-purpose grease through the selftapping lube fitting to lubricate the self-align bearing and the cylinder-mount pin (if required).

8. Install the drive shaft assemblies. Refer to Section

5.4.5, “Drive Shaft Installation.”

9. If reinstalling an axle previously removed from the machine, position the driveshaft yoke on the axle according to the alignment marks made earlier. If installing a new axle, note the position of the driveshaft yoke at the transmission. Align the driveshaf t yo ke o n t he axle in the same pl a ne as th e yoke on the transmission.

10. Tighten the axle oil drain plug, loosen and remove the axle oil fill plug (3). Fill the axle through the axle fill plug until the oil level is even with the oil check level plugs (4). Refe r to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.

11. Rotate wheel hubs 90 degrees so the drain plug (5) becomes the fill plug. Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.

12. Install the wheel and tire assemblies. Refer to Section 5.5.2, “Installing Wheel and Tire Assembly onto Machine.”

13. Carefully remove the jack, hoist or overhead crane and sling supporting the axle.

14. Carefully raise the machine using a suitable jack or hoist. Remove the supports from beneath the frame and lower the machine to the ground.

Note: ALWAYS use new o-rings when servicing the machine.

15. Install new o-rings into the fittings. Lubricate the o-rings with clean hydraulic oil.

16. Uncap and connect the steering and brake lines at their axle fittings.

17. Install the park brake on the front axle (8, 9, 12 & 13M only).

18. If reinstalling the front axle, the hydraulic brake circuit will need to be bled. Refer to Section 8.9.3, “Brake Test.”

19. Check the hydraulic reservoir oil level.

20. Install the fender assemblies.

21. Properly connect the battery.

22. Unblock the wheels.

23. Start the engine. Turn the steering wheel several times lock to lock, operate the frame tilt funct ion several times in both directions and check the function of the brakes. Check for hydraulic leaks, and tighten or repair as necessary.

24. Close and secure the engine cover.

25. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5-5

Axles, Drive Shafts, Wheels and Tires

5.3.7 Axle Assembly and Drive Shaft Troubleshooting

Problem Cause Remedy

1. Excessive axle noise while driving.

1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Axle and/or wheel end housings

filled with incorrect oil or oil level low.

2. Drain axle and/or wheel end housings and fill to correct level

with Mobilfluid 424

ISO 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

3. Incorrect alignment of ring and pinion gears.

4. Incorrect pinion (input) shaft bearing preload.

3. Correct alignment by adding or removing shims as needed.

4. Correct bearing preload by adding or removing shims as needed.

5. Worn or damaged bearings. 5. Replace bearings as needed.

6. Worn or broken gear teeth. 6. Replace gears as needed.

7. Contamination in the axle. 7. Drain axle and/or wheel end housings and fill to correct level

with Mobilfluid 424

ISO 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Intermittent noise when traveling.

3. Vibration or intermittent noise when traveling.

8. Axle housing damaged. 8. Replace damaged parts.

1. Universal joint(s) worn or damaged.

2. Differential ring and/or pinion gears damaged.

1. Drive shaft universal joint assembly(ies) incorrectly

1. Repair or replace universal joints as needed.

2. Determine cause and repair as needed.

1. Tighten capscrews to correct torque.

tightened.

2. Drive shaft universal joint(s) worn or damaged.

3. Drive shaft(s) damaged/ unbalanced.

2. Repair or replace universal joints as needed.

3. Replace drive shaft(s) as needed.

5-6

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

4. Oil leaking from axle (differential housing and/or axle housings).

1. Drain and/or inspection plugs loose and/or o-rings damaged or missing.

2. Hose fittings loose. 2. Tighten fittings.

3. Axle shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Input shaft multi-seal ring damaged or missing and/or worn or damaged pinion (input) shaft sealing surface s.

5. Axle casing to brake housing and/or brake housing to differential assembly o-rings and/or seals worn or damaged.

6. Axle housing mounting nuts and capscrews loose.

7. Differential and/or axle housing(s) damaged.

1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft).

3. Replace seal and/or joint coupling fork shaft (axle shaft).

4. Replace multi-seal ring and/or input shaft. Adjust ring and pinion alignment and bearing preload as described in the Dana Repair Manuals.

5. Replace o-rings and seals.

6. Tighten housing nuts and capscrews to 390 Nm (288 lb-ft).

7. Replace housing(s) as needed.

5. Oil leaking from wheel end housing (planet carrier).

6. Oil leaking from steering cylinder.

1. Oil level plugs loose and/or o-rings damaged or missing.

2. O-ring between hub and housing (planet carrier) damaged or missing.

3. Shaft seal damaged or missing and/or worn or damaged shaft sealing surfaces.

4. Housing capscrews loose. 4. Tighten housing capscrews to

5. Housing (planet carrier) damaged. 5. Replace housing (planet carrier).

1. Hose fittings loose. 1. Tighten fittings.

2. Steering cylinder o-rings and/or seals worn or damaged.

3. Piston rod seal worn or damaged.

4. Cylinder tube damaged. 4. Replace cylinder tube.

1. Replace o-rings as needed and tighten plugs to 130 Nm (96 lb-ft).

2. Replace o-ring.

3. Replace seal and/or fork joint shaft.

55 Nm (41 lb-ft).

2. Replace o-rings and seals.

3. Replace piston rod seal.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5-7

Axles, Drive Shafts, Wheels and Tires

Problem Cause Remedy

7. Axle overheating. 1. Oil level too high. 1. Fill oil to correct level with

Mobilfluid 42 4

ISO 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Axle and/or wheel end housings filled with incorrect oil or oil contaminated or oil level low.

2. Drain axle and fill to correct level

with Mobilfluid 424

ISO 46. Refer toSection 2.4, “Fluids, Lubricants and Capacities.”

3. Dragging park brake. 3. Adjust park brake cable as needed.

8. High steering effort required. 1. Steering (hydraulic) system not operating properly.

2. Excessive joint housing swivel bearing preload.

1. Refer to Section 8.10.8, “Steering Cylinders.”

2. Correct bearing preload by adding or removing shims as needed.

3. Worn or damaged swivel bearings.

9. Slow steering respo nse. 1. Steering (hydraulic) system not operating properly.

2. Steering cylinder leaking internally.

3. Replace swivel bearings as needed.

1. Refer to Section 8.10.8, “Steering Cylinders.”

2. Repair or replace steering cylinder as needed.

10. Excessive noise when brakes

1. Brake discs worn. 1. Check brake discs for wear.

are engaged.

2. Brake discs damaged. 2. Replace brake discs.

11. Brakes will not engage. 1. Brake (hydraulic) system not operating properly.

2. Brake piston o-rings and seals damaged (leaking).

12. Brakes will not hold the

1. Brake discs worn. 1. Check brake discs for wear.

machine or braking power reduced.

2. Brake (hydraulic) system not operating properly.

3. Brake piston o-rings and seals damaged (leaking).

Refer to Section 5.6, “Brakes.”

1. Refer to Section 8.10.8, “Steering Cylinders.”

2. Replace o-rings and seals.

Refer to Section 5.6, “Brakes.”

2. Refer to Section 8.9.3, “Brake Test.”

3. Replace o-rings and seals.

5-8

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5.4 DRIVE SHAFTS

To Transmission

To Axle

5.4.1 Drive Shaft Inspection and Service

Whenever servicing the machine, conduct a visual inspection of the drive shaft and cross and bearing assembly (universal joints, or U-joints). A few moments spent doing this can help prevent further problems and down time lat er .

Inspect area where the drive shaft flange yoke and slip yoke mount to the drive shaft. Attempt to turn drive shaft in both directions. Look for excessive looseness, missing parts, cracks or other damage. Worn or damaged drive shaft and cross and bearing assembly may cause an excessive amount of vibration or noise.

Note: Any bolt removed from the drive shaft assembly MUST be replaced. Do Not re-torque.

5.4.2 Drive Shaft Maintenance

Refer to Section 2.6, “Lubrication Schedules,” for information regarding the lubrication of the grease fittings on the drive shafts.

5.4.3 Drive Shaft Removal

2. Place a Do Not Operate T ag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the engine to cool.

4. Properly disconnect the battery.

5. Block the wheels.

6. The drive shaft assembly is a balanced assembly. Mark the yoke and axle, transmission and the shaft and slip yoke so that these components can be returned to their original positions when reinstalled. Yokes at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

Axles, Drive Shafts, Wheels and Tires

7. Remove the four capscrews (1) and two straps (2) securing the bearing cross to the transmission output shaft flange. Discard capscrews.

8. Remove the fo ur ca pscr ews (3) and two straps (4) securing the bearing crosse s to the ax le . Discard capscrews.

9. Remove the front drive shaft assembly.

10. Repeat the above procedure for the rear drive shaft.

5.4.4 Drive Shaft Cleaning and Drying

1. Disassemble and clean all parts using an approved cleaning fluid. Allow to dry.

2. Remove any burrs or rough spots from all machined surfaces. Re-clean and dry as required.

5.4.5 Drive Shaft Installation

Note: The yoke at both ends of the drive shaft must be in the same plane to help prevent excessive vibration.

1. Raise the drive shaft assembly into position. The slip-yoke end of the drive shaft mounts toward the axle. If reinstalling a drive shaft previously removed, align the flange yokes according to the alignment marks made during removal.

2. Install the four capscrews and two straps securing the bearing crosses to the transmission. Torque the capscrews to 38 Nm (28 lb-ft).

3. Install the four capscrews and two straps securing the bearing crosses to the axle. Torque the capscrews to 38 Nm (28 lb-ft).

4. Repeat the above procedure on the rear drive shaft.

5. Properly connect the battery.

6. Unblock the wheels.

7. Close and secure the engine cover.

8. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

5-9

Axles, Drive Shafts, Wheels and Tires

MY4190

5.5 WHEELS AND T IRES

WARNING

Mismatched tire sizes, ply ratings or mixing of tire types (radial tires with bias-ply tires) may compromise machine stability and may cause machine to tip over.

JLG recommends a replacement tire to be the same size, ply and brand as originally installed. Refer to the appropriate parts manual for ordering information. If not using a JLG approved replacement tire, JLG recommends that replacemen t tire s have the foll owi ng characteristics:

• Equal or greater ply/load rating and size of original.

• Tire tread contact width equal or greater than

original.

• Wheel diameter, width and offset dimensions equal to the original.

• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load).

The rims installed have been designed for stability requirements which consist of track width, tire pressure and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in unsafe condition regarding stability.

The tires are filled with air only when the machine leaves the factory. JLG does not recommend the use of hydrofill as a tire-fill substance because of possible environmental impact.

Large-bore valve stems are used to help expedite tire inflation and deflation. An inner tube may be used if a tire does not provide an airtight seal. Check tire inflation pressures when the tires are cold. When mounting a tire on the wheel, the tire must be mounted on the wheel respective of the directional tread pattern of the tire; this produces a left or right tire and wheel assembly.

The wheel and tire assemblies must be installed with the directional tread pattern “arrows” (5) facing in the direction of forward trave l.

5.5.1 Removing Wheel and Tire Assembly from Machine

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Loosen, but DO NOT remove the lug nuts on the wheel and tire assembly to be removed.

4. Place a suitable jack under the axle pad closest to the wheel being removed. Raise the machine and position a suitable support beneath the axle. Allow sufficient room to lower the machine onto the support and to remove the wheel and tire assembly.

5. Lower the machine onto the support.

6. Remove lug nuts and lug washers in an alternating pattern.

7. Remove the wheel and tire assembly from the machine.

5-10

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Axles, Drive Shafts, Wheels and Tires

Mh3300

Tread "arrows" must point

forward

Install tires onto wheels to

rotate in proper direction

MY4200

MZ1030

MZ5830

5.5.2 Installing Wheel and Tire Assembly onto Machine

Note: The wheel and tire assemblies must be installed with the directional tread pattern “arrows” facing in the direction of forward travel.

5.6 BRAKES

5.6.1 Brake Disk Inspection.

a. Front and Rear Axles

1. Block all four wheels to help prevent the machine from moving after the parking brake is disabled.

2. Remove the oil-level plug (6) on each side of the axle.

3. Have an assistant sit in the cab and apply the brakes, keeping pressure applied.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

1. Position wheel onto studs on wheel end of axle.

2. Install wheel lug washers.

3. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

4. Tighten lug nuts in an alternating pattern as indicated in figure. Torque to 575 Nm (424 lb-ft).

5. Remove machine from supports.

6. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

4. Using a feeler gauge, check the gap between the brake discs (7). If the gap is less than 4,5 mm (0.18 in), replace the brake discs.

Note: If the brake discs are worn beyond their tolerance, the brake disc must be replaced on both sides of the axle at the same time.

5. Repeat steps 3 and 4 for the other side of the axle.

6. Fill the axle through the axle fill plug (8) until the oil level is even with the oil check level plugs (6). Refer to Section 2.4, “Fluids, Lubricants and Capacities,” for proper oil and capacities.

5-11

Axles, Drive Shafts, Wheels and Tires

MZ1020

5.7 TOWING A DISABLED MACHINE

Towing a disabled machine should only be attempted as a last resort, after exhausting all other options. Make every effort to repair the machine, and move it under its own power, before using the emergency towing procedures outlined belo w.

On 17M machines, the park brake is hydraulically operated. Therefore, the axle must have the park brake manually be disabled. On 8, 9, 12 & 13M machines, the park brake is cable operated and can be disabled in the cab with the park brake lever.

5.7.1 Towing (8, 9, 12 & 13M)

1. Secure the machine to a suitable towing vehicle.

2. Release the park brake and set the transmission control lever in (N) NEUTRAL.

3. Tow the machine to a suitable repair facility.

4. After towing is complete, engage the park brake.

5.7.2 Manually Releasing the Park Brake (17M)

Note: Block the wheels of the machine BEFORE attempting to release the park brake. Once the park brake is released the machine’s park brake AND service brakes are inoperable.

Note: Turning the release bolts in to far could warp the brake discs. DO NOT over tighten.

Note: After the machine has been towed to a secure location, reactivate the park brake. Carefully follow the procedures from start to finish. Consult your local JLG distributor or the JLG Service Department if you are unsure about any part of the procedure, or for specific instructions concerning your particular situation.

5.7.3 Manually Resetting the Park Brake (17M)

Note: Block the wheels of the machine BEFORE attempting to reset the machine’s park brake. Once the park brake is reset the machine’s park brake AND service brakes are operable.

1. Loosen the jam nuts on all four manual brake release bolts.

2. Turn all four manual brake release bolts OUT a quarter turn at a time to the dimension recorded before starting the towing procedure.

3. Tighten the jam nuts on all four manual brake release bolts.

After repairs to the machine have been made, start the machine and check the park brake and service brakes for proper function.

1. Measure the distance from the bolt head to the face of the jam nut on all four of the manual brake release bolts (9) located on each side of the front axle center section (two per side). Record the measurements.

2. Loosen the jam nuts on the four manual brake release bolts.

3. Turn all four release bolts in equally with a wrench or socket BY HAND a quarter turn at a time up to approximately 19 mm (0.750 in) or until resistance is felt. Tighten the jam nuts.

5-12

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section 6

Transmission:

Contents

PARAGRAPH TITLE PAGE

6.1 Transmission Assembly Component Terminology . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2 Transmission Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3 Transmission Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 Transmission Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.1 Transmission Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4.2 Transmission Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5 Transmission Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.5.1 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6.5.2 Transmission Inspection and Internal Repair . . . . . . . . . . . . . . . . . . . . . . 6-5

6.5.3 Transmission Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.5.4 After Transmission Service or Replacement. . . . . . . . . . . . . . . . . . . . . . . 6-6

6.6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

6-1

Transmission:

MZ0670

OUTPUT SHAFT

(FRONT)

TORQUE CONVERTOR

DIPSTICK AND FILL TUBE

BREATHER

OUTPUT SHAFT

(REAR)

DROP BOX OIL LEVEL

SIGHT GAUGE

BREATHER

TRANSMISSION DROP BOX

FLEX PLATE ASSEMBLY

SHIFT SOLENOIDS

OIL FILTER

6.1 TRANSM I SSION ASSEMBLY COMPONENT TERMINOLOGY

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.

6-2

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

WARNING

Transmission:

6.4.2 Transmission Maintenance Schedule

Complete transmission maintenance information is located in the appropriate Operation & Safety Manual.

DO NOT service the machine without following all safety precautions as outlined in Section 1, “Safety Practices,” of this manual.

6.2 TRANSMISSION DESCRIPTION

Instructions in this section p erta in mai nly to ge ne ral specifications, towing, m ainte nan ce i nf ormat ion , and transmission removal and installation procedur es. For internal transmission service instructi ons and detailed specificat ions contact your local authorized service distributor for a copy of the Dana Spicer Repair Manual (P/N 31200163).

6.3 TRANSMISSION SERIAL NUMBER

The transmission serial number plate is located on the front of the transmission case below the convertor housing. Information specified on the serial number plate includes the transmission model number, the transmission serial numbe r and other data . Informati on on the serial number plate is required in correspondence regarding the transmission.

6.4 TRANSMISSION SPECIFICATIONS

6.4.1 Transmission Maintenance

Cleanliness is of ex trem e impo rtan ce. Be fo r e att emp tin g any repairs, thoro ughly cl ean t he ext erio r of t he transmission to help prevent dirt from entering while performing maintenance checks and proce dures.

Section 2.5, “Maintenance Schedules.” provides a suggested maintenance schedule with references to pertinent procedures and instructions in this manual. To help prevent transmission problems before they occur, follow the maintenance schedule.

Note: Lubrication and Maintenance chart decals are located inside the rear door of the machine or in the cab. These decals contain a general maintenance schedule that should be followed to maintain the machine in good operating condition. Refer to Section 2.6, “Lubrication Schedules.” The same schedule information is presented in the appropriate Operation & Safety Manual, with a detailed account of how to perform the procedures.

• At ten hour intervals, check the transmission oil level. Refer to the appropriate Operation & Safety Manual.

• When the machine completes it’s first 50 hours of use, change the transmission filter. Change the filter only; DO NOT change the transmission oil at the first 50 hour maintenance level. Refer to the appropriate Operation & Safety Manual.

• At 1,000 hour intervals, change the transmission oil and filter. Refer to the appropriate Operation & Safety Manual.

Periodically, depending on operating conditions and other factors, back flush the transmission oil cooler, which is located in or behind the radiator. ALWAYS back flush the transmission oil cooler after removing the transmission for repair or replaceme nt.

The transmission oil cooler outlet hose, routed to the lower oil cooler fitting, is located on the top of the transmission. The transmission oil cooler inlet hose, routed to the upper oil cooler fitting, is located on the top of the transmission Refer to Section 7.4, “Engine Cooling System.”

Disconnect and back flush the oil cooler portion of the radiator or the oil cooler with oil and compressed air until all foreign material is removed. If necessary, remove the radiator or oil cooler from the machine, and clean the oil cooler circuit using oil, compressed air and steam.

Note: DO NOT use flushing compounds for cleaning purposes.

6.5 TRANSMISSION REPLACEMENT

Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period.

Note: To help ensure safety and optimum performance, replace the transmission if it is damaged. Refer to the appropriate Parts Manual for ordering information.

Cleanliness is of extreme importance. Before attempting to remove the transmission, thoroughly clean the exterior of the transmission to help prevent dirt from entering during the replacement process. Avoid spraying water or cleaning solution onto or near the transmission shift solenoids and other elect rica l com pon ents .

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

6-3

Transmission:

MZ1380

6.5.1 T ransmission Removal

WARNING

Risk of severe personal injury. NEVER lift a transmission alone; enlist the help of at least one assistant or use a suitable hoist or overhead crane and sling.

1. Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the transmission control lever in the (N) NEUTRAL, engage the park brake and shut the engine OFF.

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stating that the machine should not be operated.

3. Open the engine cover. Allow the engine to cool.

4. Remove the engine cover to allow easier access to the transmission.

5. Remove the belly pan from under engine.

6. Disconnect the (+) positive and (-) negative battery cables and remove the battery.

7. Thoroughly clean the transmission and surrounding area, including all hoses and fittings, before proceeding.

8. Place a suitable receptacle under the transmission drain plug (1). Remove the transmission drain plug and allow the transmission oil to drain into the receptacle. Repeat drain procedure with the drop box (2).

9. Transfer the used transmission oil into a suitable, covered container, and label the container "Used Oil". Dispose of used oil at an approved recycling facility. Clean and reinstall the transmission drain plug.

10. Remove the drive shafts. Refer to Section 5.4.3, “Drive Shaft Removal.”

11. Remove the air cleaner unit and intake tubes.

12. Remove the hydraulic pu m p. Re fe r to Sec ti o n 8. 7 . 3, “Pump Replacement.”

13. Label and disconnect the transmission temperature switch connector and sh ift sol en oid wiring harness connectors.

14. Label, disconnect and cap the transmission oil cooler inlet and outlet hoses at the transmission. The transmission oil cooler outlet hose, routed to the lower radiator fitting, is located on the top of the transmission. the transmission oil cooler inlet hose, routed to the upper radiator fitting, is located on top of the transmission.

15. Remove the access plug from the side of the engine bell housing. This will allow access to remove the eight bolts holding the flex plate to the engine flywheel.

16. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Remove them one at a time.

17. Wipe up any spilled hydraulic and transmission oil.

18. Connect a lifting strap or chain to the lifting eye at the top of the transmission, and to a suitable hoist or overhead crane. Operate the hoist or crane to remove slack from the chain, but DO NOT raise the transmission at this time.

19. Place blocks under the rear of engine for support BEFORE transmission mounts are removed.

20. Place blocks under the transmission to help support it during removal.

21. Remove both rear transmission mount bolts and lockwashers securing the transmission mount to the frame.

22. Remove the ten bolts and washers holding the transmission to the engine.

23. Remove the four capscrews and four lockwashers securing each rear transmission mount to the transmission.

24. Remove the two transmission mounts from the machine.

25. Inspect the rubber mounts. Replace the mounts if damaged.

26. Carefully remove the transmission from the machine. Avoid causing damage to the transmission or surrounding parts.

6-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Transmission:

MZ0680

27. Lift the transmission clear of the machine, and lower it onto suitable supports or secure it to a stand built especially for transmission or engine service. Secure the transmission so that it will not move or fall.

28. Remove any external transmission components as required, including the transmission temperature switch, and inlet and outlet cooler hose fittings. Cover all transmissi on ope nin gs .

29. Remove the transmission oil filter (3) and dispose of properly. Clean the filter mounting surface. Cover or cap the oil filter mount.

30. If transmission oil is suspected of contamination or torque convertor is damaged, remove the convertor and flex plate from the transmission.

31. Remove the six bolts and washers holding the convertor to the flex plate.

6.5.2 Transmission Inspection and Internal

Repair

If replacing the entire transmission, transfer the transmission temperature switch to the replacement transmission. The gear shift solenoids are included with a new transmission.

Detailed internal service instructions are provided in the Dana Spicer Repair Manual, which can be obtained by contacting your local JLG Distributor.

6.5.3 Transmission Installation

1. Install both the rear transmission mounts on the transmission. Torque capscrews to 120 Nm (88 lb-ft).

2. Install guide studs near the top of the bell housing holes and in the flex plate.

3. Use a hoist or overhead crane and sling attached to the lifting eye at the top of the transmission. Raise and position the transmission within the chassis.

4. Align the torque convertor, align the transmission bolt holes with the guide studs in the bell housing and flex plate. Install the eight bolts and washers and torque to 63 Nm (46 lb-ft). Remove the alignment studs and install and torque the last two transmission mount bolts and torque to 63 Nm (46 lb-ft).

5. Install the two rear transmission mounting bolts on the frame with two capscrews and two lockwashers. Apply Loctite and torque to 210 Nm (155 lb-ft).

6. Turn the engine over slowly by hand and align each of the eight flex plate bolts to be accessed. Install them one at a time. Torque to 35-39 Nm (26-29 lb-ft). Replace access plug.

7. Remove the hoist or overhead crane and sling.

8. Connect the transmission temperature switch connector and shift solenoid wiring harness connectors.

9. Secure the wiring harness to the transm is si on housing.

10. Uncap and connect the transmission oil cooler inlet and outlet hoses at the transmission.

11. Install the hydraulic pump. Refer to Section 8.7.3, “Pump Replacement.”

12. Install the transmission-to-axle drive shafts. Refer to Section 5.4.5, “Drive Shaft Installation.”

13. Install air cleaner and tubing.

14. Clean the transmission oil filter mounting surface.

15. Apply a thin film of clean hydraulic oil to the new transmission filter gasket. Install the new filter and torque to 27-34 Nm (20-25 lb-ft).

243TM to the transmission mount bolts

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

6-5

Transmission:

MZ0680

16. Remove the dipstick and add approximately 11,4 liters (3 Gallons) of hydraulic oil. Check the oil level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.

17. Remove the fill plug on the transfer case. Fill the transmission drop box. Refer to Section 2.4, “Fluids, Lubricants and Capacities.” Install and tighten drop box fill plug.

18. Install the belly pan under the engine.

19. Install the engine cover.

20. Install the battery and reconnect the positive (+) and negative (-) cables.

21. Close and secure the engine cover.

22. Remove the Do Not Operate Tags from both the ignition key switch and the steering wheel.

6.5.4 After Transmission Service or

Replacement

Refer to the Dana Spicer Transmission Repair Manual which can be obtained by calling your local JLG Distributor.

In General:

1. Check the transmission oil level and add oil as required.

2. Check the transmission drop box oil level and add oil as required.

3. Install a new transmission filter.

4. Check the torque on the drive shaft yoke capscrews.

5. Wear suitable eye protection. When an overhauled or repaired transmission is installed, thoroughly clean the oil cooler lines to and from the transmission.

6. Drain and flush the entire system.

7. Disconnect and clean all transmission cooler hoses. When possible, remove transmission lines from the machine for cleaning.

8. Thoroughly clean transmission filter screens and cases, and replace transmission filter elements.

9. Thoroughly clean transmission oil cooler.

10. Reassemble all components and fill the transmission through the dipstick tube opening (4). Remove the dipstick and fill with approximately 11 liters (2.5 gallons) of hydraulic. Check the level by taking intermittent dipstick readings as outlined in the appropriate Operation & Safety Manual. DO NOT overfill. Reinstall the dipstick when finished.

11. Run the engine for two minutes at idle to help prime the torque convertor and the transmission oil lines.

12. Recheck the level of the oil in the transmission with the engine running at idle.

13. Add hydraulic oil as necessary to bring the oil level up until it reaches the FULL mark on the dipstick. Recheck the oil level when it reaches operating temperature 83-94°C (180-200°F).

14. Recheck all drain plugs, lines, connections, etc. for leaks, and tighten where necessary.

6-6

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Transmission:

6.6 TROUBLESHOOTING

The transmission should be checked, serviced and

repaired only by experienced service technicians who are This section provides an easy reference guide covering the most common problems that may occur during

aware of all safety instructions and particular component

features. operation of the transmission.

Note: Contact the JLG Service Department if internal transmission repair is required during the warranty period.

Problem Cause Remedy

1. Transmission will not engage or will not shift properly.

1. Oil level too high or low. 1. Fill transmission to correct level with Mobilfluid 424 Grade 46. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

2. Transmission cont rol lever not

functioning properly and/or a

2. Refer to Section 9.7.1, “Cab Harness Electric al Schematic.”

fault in the wiring harness.Transmission control lever not functioning properly and/or a fault in the wiring harness.

ISO

3. Transmission valve body solenoids not functioning

3. Refer to Section 9.7.1, “Cab Harness Electric al Schematic.”

properly.

4. Pilot-operated shift valves not operating properly.

4. Clean the valve spool and housing. Replace return spring as needed.

5. Pump output pressure low. 5. Refer to Section 6.6, “Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”

6. Clutch piston o-rings damaged. 6. Replace o-rings.

7. Clutch discs worn or damaged. 7. Replace clutch discs.

8. Coupling shafts or gear teeth

8. Replace couplings.

damaged.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

6-7

Transmission:

Problem Cause Remedy

2. Low or no pump flow or pressure.

1. Low oil level. 1. Fill transmission to correct level

with Mobilfluid 424

ISO Grade 46. (Refer to Section 2.4, “Fluids, Lubricants and Capacities.”)

2. Transmission filled with incorrect oil, or oil contaminated.

2. Drain transmission and fill to correct level with Mobilflu id 424 ISO Grade 46. (Refer Section

2.4, “Fluids, Lubricants and Capacities.”)

3. Pump suction pipe screen clogged.

3. Clean, repair and/or replace suction pipe.

4. Central shaft damaged. 4. Replace central shaft.

5. Pump worn or damaged. 5. Repair or replace pump assembly.

3. Low clutch pressure. 1. Incorrec t oil level. 1. Fill transmission to correct level

with Mobilfluid 424

ISO Grade 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Main pressure valve stuck open. 2. Clean the valve spool and housing.

3. Broken or worn coupling shaft or

3. Replace coupling and/or o-rings.

piston o-rings.

4. Pressure reducing valve stuck

open.

4. Clean the valve spool and housing.

4. Lack of power. 1. Park or service brake dragging. 1. Refer to Section 8.5, “Hydraulic Schematics.”

2. Low engine rpm causes converter stall.

2. Adjust the engine rpm to specifications. Refer to DanaSpicer Service Manual.

3. Pump output pressure is low. 3. Refer to Section 6.6, “Troubleshooting,” Problem 2. “Low or no pump flow or pressure.”

4. Clutch discs worn or damaged. 4. Replace clutch discs.

5. Transmission overheating. 5. Refer to Section 6.6, “Troubleshooting,” Problem 5. “Transmission overheating (oil above 120° C (248° F)).”

6-8

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Problem Cause Remedy

Transmission:

5. Transmission overheating (oil above 120° C (248° F)).

6. Grinding or “clunking” noise from transmission.

1. Low oil level. 1. Fill transmission to correct level

with Mobilfluid 424

ISO Grade 46. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. Clogged radiator. 2. Remo ve deb ris fro m the radiator.

3. T ransmission fille d with incorrect

oil, or oil contaminated.

3. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section

2.4, “Fluids, Lubricants and Capacities.”

4. Excessive “roading.” 4. Stop and idle the engine.

5. Restriction in oil cooler hoses. 5. Replace cooler hoses.

6. Pump worn or damaged. 6. Repair or replace pump assembly.

7. Engine thermostat stuck. 7. Replace engine thermostat. Refer to Section 7.4.2, “Thermostat Replacement.”

1. Oil level too low. 1. Fill oil to correct level. Refer to Section 2.4, “Fluids, Lubricants and Capacities.”

2. T ransmission fille d with incorrect

oil.

2. Drain transmission and fill to correct level with Mobilfluid 424 ISO Grade 46. Refer to Section

2.4, “Fluids, Lubricants and Capacities.”

3. Incorrect clutch engagement. 3. Refer to Section 9.14.1, “Transmission Solenoid Valves.”

4. Internal damage. 4. Repair or replace parts as needed.

5. Broken diaphragm (flex plate). 5. Replace diaphragm (flex plate). Refer to Section 6.5.1, “Transmission Removal.”

6. Loose diaphragm (flex plate)

6. Tighten capscrews.

mounting capscrews.

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

6-9

Transmission:

Problem Cause Remedy

7. Oil leaking from transmission. 1. Oil leaking from vent (high oil

level).

2. Drain plug loose and/or o-rings damaged or missing.

3. Hose fittings loose. 3. Tighten fittings.

4. Oil leaking at valve bodies (possible valve body gaskets damaged or missing and/or mounting capscrews not tigh t) .

5. Housing capscrews loose. 5. Tighten capscrews to 46 Nm

6. Oil leaking at pump (possible pump-to-housing o-rings missing or damaged, and/or pump mounting capscrews not tight).

1. Remo ve dr ain plug and dra in o il as needed, until oil is at correct level. Refer to Section 2.4, “Fluids, Lubricants and Capacities.” Replace o-rings as needed and tighten plugs to 130 Nm (96 lb- ft ).

2. Replace o-rings as needed and tighten plug to 35 Nm (26 lb-ft).

4. Replace gaskets and/or tighten capscrews to 9,5 Nm (7 lb-ft).

(34 lb-ft).

6. Replace o-rings and/or tighten capscrews to 115 Nm (85 lb-ft).

7. Oil leaking at converter bell (possible converter leak and/or input shaft seal damage).

8. Oil leaking at output shaft (output shaft seal damaged).

9. Housing damaged. 9. Replace housing as needed.

7. Replace converter and/or input shaft seal.

8. Replace output shaft seal.

6-10

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

Section 7

Engine: Perkins 1104-42 & 1104-42T

Contents

PARAGRAPH TITLE PAGE

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.1.1 Disclaimer and Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.1.2 Component Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.2 Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3 Specifications and Maintenance Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4.1 Radiator Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4.2 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.4.3 Radiator/Oil Cooler and Coolant Heater Replacement. . . . . . . . . . . . . . . 7-5

7.5 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.6.1 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.6.2 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7.6.3 After Fuel System Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.7 Engine Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7.8 Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.8.1 Air Cleaner Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.8.2 Air Cleaner Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.9 Engine Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.9.1 Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7.9.2 Engine Disassembly, Inspection and Service . . . . . . . . . . . . . . . . . . . . . . 7-10

7.9.3 Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.10 Engine Drive Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.10.1 Drive Plate Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.10.2 Drive Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7.11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

7-1

Engine: Perkins 1104-42 & 1104-42T

7.1 INTRODUCTION

7.1.1 Disclaimer and Scope

These instructions are written for worldwide use. In territories where legal requirements govern engine smoke emission, noise, safety factors, etc., apply all instructions, data and dimensions provided herein in such a way that after maintenance, service and repair of the engine, engine operation does not violate local regulations.

Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. For assistance with comprehensive engine diagnosis, repair and component replacement, contact your local Perkins Service partner.

A gradual running-in (break-in) of a new engine is not necessary. Full load can be applied to a new engine as soon as the engine is put into service and the coolant temperature is at least 60° C (140° F). Extended lightload operation during the early life of the engine is not recommended. DO NOT run the engine at high, no-load speeds. DO NOT apply an overload to the engine.

7-2

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

7.1.2 Component Terminology

MZ0070

TURBOCHARGER

FUEL INJECTION

PUMP

OIL FILTER

THERMOSTAT

FUEL FILTER

ALTERNATOR

STARTER

To understand the safety, operation and maintenance information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the engine components. The following illustration identifies the components that are referred to throughout this section.

Engine: Perkins 1104-42 & 1104-42T

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

7-3

Engine: Perkins 1104-42 & 1104-42T

MZ2180

7.2 ENGINE SERIAL NUMBER

The Perkins serial number is stamped on a plate which is secured to the engine block, near the fuel injector pump. Information contained in the serial number is required in correspondence with the engine manufacturer.

7.3 SPECIFICATIONS AND MAINTENANCE INFORMATION

For engine, coolant and oil specifications, and maintenance information, refer to Section 2, “General Information and Specification s . ”

Note: These instructions cover only the routine maintenance, removal, installation and troubleshooting of the engine. Refer to your local Perkins Engine Distributor for assistance with comprehensive engine diagnosis, repair and component replacement.

7.4 ENGINE COOLING SYSTEM

7.4.1 Radiator Pressure Cap

For a 99° C (210° F) system, use a 90 kPa (13 psi) radiator cap. An incorrect or malfunctioning cap can result in the loss of coolant and a hot-running engine.

a. Thermostat Removal

2. Place a Do Not Operate Tag on both the ignition key switch and steering wheel, stati ng that the machi ne should not be operated.

3. Open the engine cover. Allow the system fluids to cool.

4. Properly disconnect the battery.

5. Slowly turn the radiator cap to the first stop and allow any pressure to escape. Remove the radiator cap.

6. Place a funnel at the base of the radiator to channel the drained coolant into the container. Loosen the drain plug and slowly remove to allow the coolant to drain. Transfer the coolant into a properly labeled container. Dispose of properly if coolant needs to be replaced. Replace the radiator drain plug.

7.4.2 Thermostat Replacement

Before considering thermostat replacement, check the coolant level, fan belt tension and instrument cluster temperature indicator.

• If the engine seems to take a long time to warm up, the thermostat may be stuck in the open position and requires replacement.

• If the engine runs hot, check the temperature of the upper radiator hose.

• If the hose is not hot, the thermostat may be stuck in the closed position.

• If the engine has overheated, performance may suffer, indicating other damage including a leaking cylinder head gasket, cracked cylinder head or block, and/or other internal engine damage.

7. Remove the two capscrews securing the thermostat housing (1) to the engine.

8. Remove the thermostat housing, old gasket and thermostat. Clean all gasket surfaces. DO NOT let any debris into the thermostat opening.

Note: ALWAYS use the correct thermostat and install a new gasket. NEVER operate the engine without a thermostat, or engine damage will result.

7-4

3508PS, 3509PS, 3512PS, 3513PS, 4008PS, 4009PS, 4012PS, 4013PS, 4017PS, 40.8, 40.9

JLG 4013PS Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 INTRODUCTION

1.2 DISCLAIMER

1.4 DO NOT OPERATE TAGS

1.5 SAFETY INFORMATION

1.5.1 Safety Alert System and Signal Words

1.3 OPERATION & SAFETY MANUAL

1.6 SAFETY INSTRUCTIONS

1.6.1 Personal Hazards

1.6.2 Equipment Hazards

1.6.3 General Hazards

1.6.4 Operational Hazards

1.7 SAFETY DECALS

2.1 REPLACEMENT PARTS AND WARRANTY INFORMATION

2.2 TORQUE CHARTS

2.2.1 SAE Fastener Torque Chart

2.2.2 Metric Fastener Torque Chart

2.2.3 Hydraulic Hose Torque Chart

2.3 SPECIFICATIONS

2.3.1 Travel Speeds

2.3.2 Hydraulic Cylinder Performance Specifications

2.3.3 Platform Hydraulic Performance Specifications

2.3.4 Electrical System

2.3.5 Engine Performance Specifications

2.3.6 Tires

2.4 FLUIDS, LUBRICANTS AND CAPACITIES

2.5 MAINTENANCE SCHEDULES

2.5.1 8 & 1st 50 Hour Maintenance Schedule

2.5.2 50, 250 & 500 Hour Maintenance Schedule

2.5.3 1000 & 1500 Hour Maintenance Schedule

2.6 LUBRICATION SCHEDULES

2.6.1 8 Hour Lubrication Schedule

2.6.2 50 Hour Lubrication Schedule

3.2 BOOM SYSTEM - TWO AND THREE SECTION BOOM

3.2.1 Boom System Description

3.3.1 Boom Removal

3.3.3 Third Section Boom Removal (12 & 13M) Second Section Boom Removal (8 & 9M)

3.3.2 Second S e c tion Bo o m Remova l (12 & 13M)

3.3.4 Third Section Boom Installation (12 & 13M) Second Section Boom Installation (8 & 9M)

3.3.5 Second Section Boom Installation (12 & 13M)

3.3.6 Boom Installation

3.4 BOOM SYSTEM COMPONENT TERMINOLOGY - FOUR SECTION BOOM

3.5 BOOM SYSTEM - FOUR SECTION BOOM

3.5.1 Boom System Operation

3.6.1 Boom Removal

3.6.4 Fourth Boom Section Removal

3.6.5 Hose Carrier Removal

3.6.6 Hose Carrier Installation

3.6.7 Fourth Boom Section Installation

3.6.8 Third and Fourth Boom Section Installation

3.6.9 Second, Third and Fourth Boom Section Installation

3.6.10 Boom Installation

3.7.1 Boom Chain Inspection

3.7.2 Inspection Guidelines

3.7.3 Expose Chains for Inspection

3.7.4 Chain Lubrication

3.8 BOOM SECTION SEPARATION ADJUSTMENT - FOUR SECTION BOOM

3.9 HOSE CARRIER ASSEMBLY - FOUR SECTION BOOM

3.9.1 Hose Carrier Assembly Removal

3.9.2 Hose Carrier Assembly Replacement

3.10 BOOM WEAR PADS

3.10.1 Wear Pad Inspection

3.10.2 Wear Pad Installation and Lubrication

3.11 QUICK SWITCH ASSEMBLY

3.1 1.1 Connecting with a Mechanical Quick Switch Device

3.11.2 Connecting with a Hydraulic Quick Switch Device

3.1 1.3 Connecting with a Quick Switch to a Hydraulic Operated Attachment

3.11.4 Quick Switch Removal

3.12 FORKS

3.11.5 Quick Switch Installation

3.13 TROUBLESHOOTING

4.1 OPERATOR CAB AND COVERS COMPONENT TERMINOLOGY

4.2 OPERATOR CAB

4.2.1 Serial Number Decal

4.3 CAB COMPONENTS

4.3.1 Steering Column and Orbitrol Valve

4.3.2 Service Brake Pedal and Valve